SM 102 Series Sebm010023 PDF

SEBM010023
This Shop Manual is made by adding the special descriptions for the 102E-2 series to the
Shop Manual for the current 102E-1 series.
2008 1
All Rights Reserved 00-1
Printed in Japan 10-08(02) (23)
CONTENTS
No. of page
01 GENERAL ............................................................................................................ 01-1
11 STRUCTURE AND FUNCTION ........................................................... 11-1
12 TESTING AND ADJUSTING ................................................................ 12-1
13 DISASSEMBLY AND ASSEMBLY ..................................................... 13-1
14 MAINTENANCE STANDARD ............................................................... 14-1
15 REPAIR AND REPLACEMENT OF PARTS .................................. 15-1
00-2 102 SERIES

2
The affected pages are indicated by the use of the
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following marks. It is requested that necessary
actions be taken to these pages according to the c Page to be newly added Add
table below.
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( ) Page to be deleted Discard
Pages having no marks are those previously re-

vised or made aditions.
LIST OF REVISED PAGES

Revision Revision Revision Revision Revision
Mark Page Mark Page Mark Page Mark Page Mark Page
number number number number number
b 00-1 (23) 01-5-2 (12) 01-22-4 (12) 11-5-1 (12) 11-30 (12)
00-2 (2) b 01-6 (23) 01-23 (12) 11-5-2 (12) 11-31
b 00-2-1 (23) b 01-7 (23) 01-24 (12) 11-5-3 (12) 11-32 (15)
b 00-2-2 (23) 01-7-1 (12) 01-25 (12) 11-5-4 (12) 11-33 (12)
b 00-2-3 (23) 01-7-2 (12) 01-26 (12) 11-5-5 (15) 11-33-1 (12)
b 00-2-4 (23) 01-7-3 (12) 01-27 (12) 11-5-6 (15) 11-33-2 (15)
00-3 01-7-5 (12) 01-27-1 (12) 11-5-7 (15) 11-34 (13)
00-4 01-7-6 (12) 01-28 (12) 11-6 (12) 11-35 (13)
00-5 01-7-7 (19) 01-29 (12) 11-7 (12) 11-36 (13)
00-6 01-7-8 (19) 01-30 (12) 11-7-1 (12) 11-37
00-7 01-7-9 (18) 01-31 (12) 11-8 (10) 11-38 (12)
00-8 01-7-10 (20) 01-32 (12) 11-9 (13) 11-40 (12)
00-9 01-7-11 (21) 01-33 (12) 11-10 (12) 11-41 (10)
00-10 01-8 (12) b 01-34 (23) 11-11 11-41-1 (12)
00-11 01-9 (12) 01-34-1 (12) 11-11-1 (12) 11-42 (12)
b 00-12 (23) 01-10 (12) 01-34-2 (12) 11-11-2 (10) 11-43 (12)
00-13 01-11 (12) 01-34-3 (12) 11-11-3 (10) 11-44 (13)
b 00-14 (23) 01-12 (12) 01-34-5 (12) 11-11-4 (10) 11-45 (12)
00-15 01-13 (12) 01-34-6 (12) 11-12 (15) 11-45-1 (12)
00-16 01-14 (12) 01-34-8 (12) 11-14 (17) 11-45-2 (12)
00-17 01-15 (12) 01-34-18 (19) 11-15 11-45-3 (12)
00-18 01-16 (12) 01-34-19 (19) 11-15-1 (17) 11-45-4 (10)
00-19 01-17 (12) 01-34-20 (10) 11-15-2 (10) 11-46
00-20 01-18 (12) 01-34-21 (13) 11-16 (15) 11-47 (13)
00-21 01-19 (12) 01-34-22 (19) 11-18 (17) 11-48 (12)
00-22 01-19-1 (15) 01-34-31 (13) 11-19 (10) 11-49 (10)
00-23 (12) 01-19-2 (15) 01-34-32 (13) 11-19-1 (17) 11-49-1 (12)
00-24 (13) 01-19-3 (15) 01-34-33 (18) 11-19-2 (10) 11-49-2 (10)
00-25 (13) 01-19-4 (15) 01-34-34 (19) 11-20 (15) 11-50
(00-26) (12) 01-19-5 (15) 01-34-35 (20) 11-21 (15) 11-51
00-27 (6) 01-19-6 (15) 01-34-36 (15) 11-22 (12) 11-52
00-28 (13) 01-19-7 (15) 01-34-37 (19) 11-23 (12) 11-53
01-19-8 (15) 01-34-38 (19) 11-24 (12) 11-55 (12)
01-1 (10) 01-20 (6) 01-35 (12) 11-25 (12) 11-55-1 (12)
b 01-1-1 (23) 01-21 (6) 01-36 (12) 11-26 (12) 11-55-2 (12)
01-1-2 (21) b 01-21-1 (23) 11-26-1 (12) 11-56 (15)
01-2 (10) 01-21-2 (20) 11-1 11-27 (17) 11-57 (10)
01-3 (12) 01-22 (12) 11-2 (12) 11-28 (12) 11-58
01-4 (12) 01-22-1 (12) 11-3 (12) 11-29 (12) 11-59 (15)
01-5 (12) 01-22-2 (12) 11-4 (12) 11-29-1 (12) 11-59-1 (12)
01-5-1 (12) 01-22-3 (12) 11-5 c 11-29-2 (23) 11-59-2 (21)
102 SERIES 00-2-1

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11-59-3 (12) 12-36 (15) 12-50-67 (19) 12-71 (1) 12-124 (1)
11-60 (13) 12-37 (15) 12-50-68 (19) 12-72 (1) 12-125 (1)
11-61 12-38 (15) 12-50-69 (19) 12-73 (10) 12-126 (10)
11-62 (13) 12-39 (15) 12-50-70 (19) 12-74 (10) 12-127 (10)
11-63 (13) 12-40 (15) 12-50-71 (12) 12-75 (1) 12-128 (1)
11-64 (21) 12-41 (15) 12-50-72 (12) 12-76 (1) 12-129 (1)
11-64-1 (19) 12-42 (15) 12-50-73 (20) 12-77 (1) 12-201 (6)
11-64-2 (19) 12-43 (15) 12-50-74 (19) 12-78 (1) 12-202 (10)
11-64-3 (19) 12-44 (15) 12-50-75 (18) 12-79 (1) 12-203 (12)
11-64-4 (19) b 12-49 (23) 12-50-76 (19) 12-80 (1) 12-204 (12)
b 11-64-5 (23) 12-49-1 (12) 12-50-77 (19) 12-81 (1) 12-205 (12)
b 11-64-6 (23) 12-49-2 (21) 12-50-78 (21) 12-82 (1) 12-206 (12)
c 11-64-7 (23) 12-50 (12) 12-51 (12) 12-83 (1) 12-206-1 (12)
11-65 (15) 12-50-1 (12) b 12-51-1 (23) 12-84 (1) 12-206-2 (12)
b 11-66 (23) 12-50-2 (12) 12-51-2 (12) 12-85 (1) 12-207 (12)
11-66-1 (20) 12-50-3 (12) 12-51-3 (12) 12-86 (1) 12-208 (12)
b 11-67 (23) 12-50-4 (12) 12-51-10 (19) 12-87 (1) b 12-209 (23)
12-50-5 (12) 12-51-11 (21) 12-88 (1) 12-210 (12)
12-1 (15) 12-50-6 (12) 12-52 (14) 12-89 (1) 12-211 (12)
12-2 (6) 12-50-7 (12) 12-53 (17) 12-90 (1) 12-212 (12)
12-3 (12) 12-50-8 (12) 12-53-1 (17) 12-91 (1) 12-213 (10)
12-4 (15) 12-50-9 (12) 12-53-2 (17) 12-92 (1) 12-220 (19)
12-5 (15) 12-50-10 (12) 12-53-3 (17) 12-93 (1) 12-221 (19)
12-6 (15) 12-50-11 (12) 12-53-4 (17) 12-94 (1) 12-221-1 (19)
12-7 (15) 12-50-12 (12) b 12-53-5 (23) 12-95 (1) 12-221-2 (22)
12-8 (15) 12-50-13 (12) 12-53-6 (17) 12-96 (1) 12-222 (21)
12-9 (12) 12-50-14 (12) 12-53-7 (17) 12-97 (1) 12-223 (20)
12-10 (12) 12-50-15 (12) 12-53-8 (17) 12-98 (1) 12-223-1 (21)
12-11 (15) 12-50-16 (12) 12-53-9 (17) 12-99 (1) 12-251 (1)
12-12 (15) 12-50-17 (12) 12-53-10 (17) 12-100 (1) 12-252 (1)
12-13 (15) 12-50-18 (12) 12-53-21 (19) 12-101 (1) 12-253 (1)
12-14 (15) 12-50-19 (12) 12-53-22 (19) 12-102 (1) 12-254 (1)
12-15 (15) 12-50-20 (12) 12-53-23 (19) 12-103 (1) 12-255 (1)
12-16 (15) 12-50-21 (12) 12-53-24 (19) 12-104 (1) 12-256 (17)
12-17 (15) b 12-50-22 (23) 12-53-25 (21) 12-105 (1) 12-257 (17)
12-18 (15) 12-50-23 (12) 12-53-26 (21) 12-106 (1) 12-258 (10)
12-19 (15) 12-50-24 (12) 12-54 (10) 12-107 (1) 12-259 (10)
12-20 (15) 12-50-25 (12) 12-55 (1) 12-108 (1) 12-260 (10)
12-21 (15) 12-50-26 (12) 12-56 (1) 12-109 (1) 12-261 (10)
12-22 (15) 12-50-27 (12) 12-57 (1) 12-110 (1) 12-262 (10)
12-23 (15) 12-50-28 (12) 12-58 (1) 12-111 (1) 12-263 (10)
12-24 (15) 12-50-29 (12) 12-59 (1) 12-112 (10) 12-264 (10)
12-25 (15) 12-50-30 (12) 12-60 (10) 12-113 (10) 12-265 (19)
12-26 (15) 12-50-31 (12) 12-61 (1) 12-114 (1) 12-266 (10)
12-27 (15) 12-50-32 (12) 12-62 (10) 12-115 (1) 12-267 (10)
12-28 (15) 12-50-33 (12) 12-63 (10) 12-116 (1) 12-268 (1)
12-29 (15) 12-50-34 (12) 12-64 (1) 12-117 (1) 12-269 (12)
12-30 (15) 12-50-35 (12) 12-65 (1) 12-118 (1) 12-270 (10)
12-31 (15) 12-50-36 (12) 12-66 (1) 12-119 (1) 12-271 (10)
12-32 (15) 12-50-40 (12) 12-67 (1) 12-120 (1) 12-272 (10)
12-33 (15) 12-50-41 (12) 12-68 (1) 12-121 (1) 12-273 (10)
12-34 (15) 12-50-51 (12) 12-69 (1) 12-122 (1) 12-274 (10)
12-35 (15) 12-50-52 (12) 12-70 (1) 12-123 (1)
00-2-2 102 SERIES

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b 13-1 (23) 13-53 (2) 13-104 (10) 13-157 (2) 13-208-1 (21)
b 13-2 (23) 13-54 (2) 13-105 (2) 13-158 (2) 13-209 (10)
b 13-3 (23) 13-55 (2) 13-106 (2) 13-159 (2) 13-210 (2)
b 13-4 (23) 13-56 (2) 13-107 (2) 13-160 (2) 13-211 (10)
b 13-5 (23) 13-57 (2) 13-108 (2) 13-161 (2) 13-212 (2)
13-6 (2) 13-58 (2) 13-109 (2) 13-162 (2) 13-213 (2)
13-7 (2) 13-59 (2) 13-110 (2) 13-163 (2) 13-214 (2)
13-8 (2) 13-60 (10) 13-111 (2) 13-164 (10) 13-215 (2)
13-9 (2) 13-61 (2) 13-112 (2) 13-164-1 (10) 13-216 (10)
13-10 (2) 13-62 (2) 13-113 (2) 13-165 (2) 13-217 (2)
13-11 (2) 13-63 (2) 13-114 (10) 13-166 (2) 13-218 (10)
13-12 (2) 13-64 (2) 13-115 (2) 13-167 (2) 13-219 (10)
13-13 (2) 13-65 (2) 13-116 (10) 13-168 (2) 13-220 (2)
13-14 (21) 13-66 (2) 13-117 (2) 13-169 (2) 13-221 (2)
13-15 (2) b 13-67 (23) 13-118 (2) 13-170 (2) 13-222 (2)
13-16 (2) c 13-67-1 (23) 13-119 (2) 13-171 (2) 13-223 (10)
13-17 (2) 13-68 (10) 13-120 (2) 13-172 (2) 13-224 (2)
13-18 (2) 13-68-1 (10) 13-121 (2) 13-173 (2) 13-225 (2)
13-19 (2) 13-69 (2) 13-122 (2) 13-174 (2) 13-226 (10)
13-20 (2) 13-70 (2) 13-123 (10) 13-175 (2) 13-227 (2)
13-21 (2) 13-71 (2) 13-124 (2) 13-176 (2) 13-228 (10)
13-22 (2) 13-72 (10) 13-125 (2) 13-177 (2) 13-229 (2)
13-23 (2) 13-73 (2) 13-126 (21) 13-178 (2) 13-230 (2)
13-24 (2) 13-74 (2) 13-127 (2) 13-179 (2) 13-231 (2)
13-25 (2) 13-75 (2) 13-128 (2) 13-180 (2) 13-232 (2)
13-26 (2) 13-76 (2) 13-129 (21) 13-181 (2) 13-233 (10)
13-27 (2) 13-77 (2) 13-130 (2) 13-182 (2) 13-234 (2)
13-28 (10) 13-78 (2) 13-131 (2) 13-183 (2) 13-235 (2)
13-29 (2) 13-79 (2) 13-132 (2) 13-184 (2) 13-236 (10)
b 13-30 (23) 13-80 (2) 13-133 (2) 13-185 (2) 13-237 (10)
b 13-31 (23) 13-81 (2) 13-134 (2) 13-186 (2) 13-238 (2)
c 13-31-1 (23) 13-82 (2) 13-135 (2) 13-187 (2) 13-239 (10)
13-32 (2) 13-83 (2) 13-136 (2) 13-188 (2) 13-240 (10)
13-33 (2) 13-84 (2) 13-137 (2) 13-189 (2) 13-241 (10)
13-34 (2) 13-85 (2) 13-138 (2) 13-190 (2) 13-242 (2)
13-35 (2) 13-86 (2) 13-139 (2) 13-191 (2) 13-243 (2)
13-36 (2) 13-87 (2) 13-140 (2) 13-192 (2) 13-244 (2)
13-37 (2) 13-88 (10) 13-141 (2) 13-193 (2) 13-245 (2)
13-38 (2) 13-89 (10) 13-142 (2) 13-194 (2) 13-246 (2)
13-39 (2) 13-90 (2) 13-143 (2) 13-195 (2) 13-247 (2)
13-40 (10) 13-91 (2) 13-144 (2) 13-196 (2) 13-248 (2)
13-41 (2) 13-92 (10) 13-145 (2) 13-197 (10) 13-249 (2)
13-42 (2) 13-93 (10) 13-146 (2) 13-198 (2) 13-250 (2)
13-43 (2) 13-94 (2) 13-147 (2) 13-199 (2) 13-251 (21)
13-44 (10) 13-95 (2) 13-148 (2) 13-200 (2) 13-252 (2)
13-45 (2) 13-96 (21) 13-149 (2) 13-201 (2) 13-253 (21)
13-46 (2) 13-97 (10) 13-150 (2) 13-202 (2) 13-254 (2)
13-47 (10) 13-98 (10) 13-151 (2) 13-203 (2) 13-255 (21)
13-48 (2) 13-99 (2) 13-152 (2) 13-204 (2) 13-256 (2)
13-49 (2) 13-100 (10) 13-153 (2) 13-205 (2) 13-257 (10)
13-50 (2) 13-101 (2) 13-154 (2) 13-206 (21) 13-258 (2)
13-51 (10) 13-102 (2) 13-155 (2) 13-207 (2) 13-260 (2)
13-52 (2) 13-103 (10) 13-156 (2) 13-208 (21) 13-261 (2)
102 SERIES 00-2-3

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13-262 (2) 13-315 (2) 13-368 (2) 13-421 (2) 15-11

13-263 (2) 13-316 (2) 13-369 (2) 13-422 (2) 15-12
13-264 (21) 13-317 (2) 13-370 (2) 13-423 (2) 15-13
13-265 (2) 13-318 (2) 13-371 (2) 13-424 (2) 15-14
13-266 (2) 13-319 (2) 13-372 (2) 13-425 (2) 15-15
13-267 (2) 13-320 (2) 13-373 (2) 13-426 (2) 15-16
13-268 (2) 13-321 (2) 13-374 (2) 13-427 (2) 15-17
13-269 (2) 13-322 (2) 13-375 (2) 13-428 (2) 15-18
13-270 (2) 13-323 (2) 13-376 (2) 15-19
13-271 (2) 13-324 (2) 13-377 (2) 14-1 (15) 15-20
13-272 (2) 13-325 (2) 13-378 (2) 14-2 (15) 15-21
13-273 (10) 13-326 (2) 13-379 (2) 14-3 (15) 15-22 (10)
13-274 (2) 13-327 (2) 13-380 (2) 14-4 (15) 15-23
13-275 (2) 13-328 (2) 13-381 (2) 14-6 (15) 15-24
13-276 (2) 13-329 (2) 13-382 (2) 14-7 (15) 15-25
13-277 (2) 13-330 (2) 13-383 (2) 14-8 (15) 15-26
13-278 (2) 13-331 (2) 13-384 (2) 14-9 (15) 15-27
13-279 (10) 13-332 (2) 13-385 (2) 14-10 (15) 15-28
13-280 (2) 13-333 (2) 13-386 (2) 14-11 (15) 15-29
13-281 (21) 13-334 (2) 13-387 (2) 14-12 (15) 15-30 (6)
13-282 (2) 13-335 (2) 13-388 (2) 14-13 (15) 15-31 (10)
13-283 (2) 13-336 (2) 13-389 (2) 14-14 (15) 15-32
13-284 (2) 13-337 (2) 13-390 (2) 14-16 (15) 15-33
13-285 (2) 13-338 (2) 13-391 (10) 14-17 (15) 15-34 (10)
13-286 (2) 13-339 (10) 13-392 (2) 14-18 (15) 15-35 (10)
13-287 (2) 13-340 (2) 13-393 (2) 14-19 (15) 15-36 (10)
13-288 (10) 13-341 (2) 13-394 (2) 14-20 (15) 15-37
13-289 (2) 13-342 (2) 13-395 (2) 14-21 (15) 15-38
13-290 (2) 13-343 (2) 13-396 (2) 14-22 (15) 15-39
13-291 (2) 13-344 (2) 13-397 (2) 14-24 (15) 15-40
13-292 (2) 13-345 (10) 13-398 (2) 14-25 (15) 15-41
13-293 (2) 13-346 (2) 13-399 (21) 14-26 (15) 15-42
13-294 (2) 13-347 (2) 13-400 (10) 14-27 (15) 15-43
13-295 (2) 13-348 (2) 13-401 (10) 14-28 (15) 15-44 (10)
13-296 (2) 13-349 (2) 13-402 (10) 14-30 (15) 15-45 (10)
13-297 (2) 13-350 (2) 13-403 (2) 14-31 (15) 15-46 (10)
13-298 (2) 13-351 (10) 13-404 (2) 14-32 (15) 15-47 (12)
13-299 (2) 13-352 (2) 13-405 (2) 14-33 (15)
13-300 (2) 13-353 (10) 13-406 (2) 14-34 (15)
13-301 (2) 13-354 (10) 13-407 (2) 14-35 (15)
13-302 (2) 13-355 (2) 13-408 (2) 14-36 (15)
13-303 (2) 13-356 (2) 13-409 (2) 14-37 (15)
13-304 (2) 13-357 (2) 13-410 (2)
13-305 (2) 13-358 (2) 13-411 (2) 15-1 (8)
13-306 (2) 13-359 (2) 13-412 (2) 15-2
13-307 (2) 13-360 (2) 13-413 (2) 15-3
13-308 (2) 13-361 (2) 13-414 (2) 15-4
13-309 (2) 13-362 (2) 13-415 (2) 15-5
13-310 (2) 13-363 (2) 13-416 (2) 15-6
13-311 (2) 13-364 (2) 13-417 (2) 15-7
13-312 (2) 13-365 (2) 13-418 (2) 15-8
13-313 (2) 13-366 (2) 13-419 (2) 15-9
13-314 (2) 13-367 (2) 13-420 (2) 15-10
00-2-4 102 SERIES

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SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

tools and removed parts. Always keep the tools
Mistakes in operation are extremely dangerous. and parts in their correct places. Always keep
Read the Operation and Maintenance Manual care- the work area clean and make sure that there is
fully BEFORE operating the machine. no dirt or oil on the floor. Smoke only in the areas
1. Before carrying out any greasing or repairs, read provided for smoking. Never smoke while work-
all the precautions given on the decals which are ing.
fixed to the machine.
2. When carrying out any operation, always PREPARATIONS FOR WORK
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons 7. Before adding oil or making any repairs, park the
missing. machine on hard, level ground, and block the
Always wear safety glasses when hitting wheels or tracks to prevent the machine from
parts with a hammer. moving.
Always wear safety glasses when grinding 8. Before starting work, lower blade, ripper, bucket
parts with a grinder, etc. or any other work equipment to the ground. If
3. If welding repairs are needed, always have a this is not possible, insert the safety pin or use
trained, experienced welder carry out the work. blocks to prevent the work equipment from fall-
When carrying out welding work, always wear ing. In addition, be sure to lock all the control
welding gloves, apron, hand shield, cap and levers and hang warning signs on them.
other clothes suited for welding work. 9. When disassembling or assembling, support the
4. When carrying out any operation with two or machine with blocks, jacks or stands before
more workers, always agree on the operating starting work.
procedure before starting. Always inform your 10.Remove all mud and oil from the steps or other
fellow workers before starting any step of the places used to get on and off the machine.
operation. Before starting work, hang UNDER Always use the handrails, ladders or steps when
REPAIR signs on the controls in the operator's getting on or off the machine. Never jump on or
compartment. off the machine. If it is impossible to use the
5. Keep all tools in good condition and learn the handrails, ladders or steps, use a stand to pro-
correct way to use them. vide safe footing.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11. When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive () terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judge-
ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte-
nance standards.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as adjustments to
be made at completion of the checks and repairs.
Troubleshooting charts correlating "Problems" with "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the procedures for removing, installing, disassembling and assembling each com-
ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL REVISED EDITION MARK
W h en a m an u a l is r e vis ed , a n e d itio n ma rk
VOLUMES
Shop manuals are issued as a guide to carrying out 123
( ....) is recorded on the bottom of the pages.
repairs. They are divided as follows:
Chassis volume: Issued for every machine model REVISIONS

Engine volume: Issued for each engine series
Revised pages are shown in the LIST OF REVISED
}
Electrical volume: Each issued as one
PAGES next to the CONTENTS page.
Attachments volume: volume to cover all
models
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
DISTRIBUTION AND UPDATING

Any additions, amendments or other changes will be
sent to KOMATSU distributors. Get the most up-to- Symbol Item Remarks
date information before you start any work.
Safety
Special safety precautions
are necessary when per-
forming the work.
FILING METHOD
1. See the page number on the bottom of the page. Special technical precau-
File the pages in correct order.
2. Following examples show how to read the page s Caution
tions or other precautions
for preserving standards
4
number. are necessary when per-
forming the work.
Example 1 (Chassis volume):
Weight of parts of sys-
10 - 3 tems. Caution necessary
3
Weight when selecting hoisting
Item number (10. Structure and wire, or when working pos-
Function) ture is important, etc.
Consecutive page number for each
2
Places that require special
item. Tightening
attention for the tightening
torque
torque during assembly.
Example 2 (Engine volume):
5
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
6
Unit number (1. Engine) Places where oil, water or
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
item. Places where oil or water
Drain m u s t b e d r a i n e d , a nd
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Heavy parts (25 kg or more) must be lifted

Slinging near the edge of the hook may cause
the rope to slip off the hook during hoisting, and
4
with a hoist, etc. In the DISASSEMBLY a serious accident can result. Hooks have max-
AND ASSEMBLY section, every part imum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol
If a part cannot be smoothly removed from the

machine by hoisting, the following checks
should be made:
1) Check for removal of all bolts fastening the 100% 88% 79% 71% 41%
part to the relative parts. SAD00479
2) Check for existence of another part causing
3) Do not sling a heavy load with one rope alone,
interference with the part to be removed.

but sling with two or more ropes symmetrically
wound onto the load.
WIRE ROPES
Slinging with one rope may cause turning
1) Use adequate ropes depending on the
of the load during hoisting, untwisting of
weight of parts to be hoisted, referring to
the rope, or slipping of the rope from its
the table below:
original winding position on the load, which
can result in a dangerous accident.
Wire ropes
(Standard "Z" or "S" twist ropes
without galvanizing) 4) Do not sling a heavy load with ropes forming a
wide hanging angle from the hook.
When hoisting a load with two or more ropes,
Rope diameter Allowable load the force subjected to each rope will increase
mm kN tons
with the hanging angles. The table below
shows the variation of allowable load kN {kg}
10 9.8 1.0 when hoisting is made with two ropes, each of
11.5 13.7 1.4 which is allowed to sling up to 9.8 kN {1000 kg}
12.5 15.7 1.6 vertically, at various hanging angles.
14 21.6 2.2 When two ropes sling a load vertically, up to
16 27.5 2.8 19.6 kN {2000 kg} of total weight can be sus-
18 35.3 3.6
pended. This weight becomes 9.8 kN {1000 kg}
20 43.1 4.4
22.4 54.9 5.6
when two ropes make a 120 hanging angle.
30 98.1 10.0 On the other hand, two ropes are subjected to
40 176.5 18.0 an excessive force as large as 39.2 kN {4000
50 274.6 28.0 kg} if they sling a 19.6 kN {2000 kg} load at a
60 392.2 40.0 lifting angle of 150.
The allowable load value is estimated to be one-

sixth or one-seventh of the breaking strength of
the rope used.
2) Sling wire ropes from the middle portion of the

hook.
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Before carrying out the following work, release

the residual pressure from the hydraulic tank.
Type 1
For details, see TESTING AND ADJUSTING,

Releasing residual pressure from hydraulic
tank.
Even if the residual pressure is released from

the hydraulic tank, some hydraulic oil flows out
when the hose is disconnected. Accordingly,
prepare an oil receiving container.
Disconnection
1) Release the residual pressure from the hydrau-
lic tan k. Fo r d e tails , se e TES TIN G AN D
ADJUSTING, Releasing residual pressure from
hydraulic tank.
2) Hold adapter (1) and push hose joint (2) into

mating adapter (3). (See Fig. 1)
The adapter can be pushed in about 3.5
mm.
Do not hold rubber cap portion (4).
3) After hose joint (2) is pushed into adapter (3),

press rubber cap portion (4) against (3) until it
clicks. (See Fig. 2)
4) Hold hose adapter (1) or hose (5) and pull it out.

(See Fig. 3)
Since some hydraulic oil flows out, prepare
an oil receiving container.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
Do not hold rubber cap portion (4).
2) After inserting the hose in the mating adapter

perfectly, pull it back to check its connecting
condition. (See Fig. 5)
When the hose is pulled back, the rubber
cap portion moves toward the hose about
3.5 mm. This does not indicate abnormality,
however.
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
Hold the mouthpiece of the tightening portion Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
Used to prevent rubber gaskets,

LT-1A 790-129-9030 150 g Tube rubber cushions, and cock plug
from coming out.
Used in places requiring an imme-

diately effective, strong adhesive.
20 g Polyethylene Used for plastics (except polyeth-
LT-1B 790-129-9050
(2 pcs.) container ylene, polyprophylene, tetrafluor-
oet hl ene and vi nyl chl oride),
rubber, metal and non-metal.
Features: Resistance to heat and

LT-2 09940-00030 50 g Polyethylene chemicals
container Used for anti-loosening and seal-
ant purpose for bolts and plugs.
Adhesive: Used as adhesive or sealant for

790-129-9060 metal, glass and plastic.
(Set of 1 kg
Hardenin
LT-3 adhesive and Can
hardening g
agent:
agent)
500 g
Adhesives
Polyethylene Used as sealant for machined

LT-4 790-129-9040 250 g holes.
container
Holtz Used as heat-resisting sealant for

MH 705 790-126-9120 75 g Tube repairing engine.
Quick hardening type adhesive

Three bond Polyethylene Cure time: within 5 sec. to 3 min.
790-129-9140 50 g
1735 container Used mainly for adhesion of met-
als, rubbers, plastics and woods.
Quick hardening type adhesive

Quick cure type (max. strength af-
Aron-alpha Polyethylene
201 790-129-9130 2g container ter 30 minutes)
Used mainly for adhesion of rub-
bers, plastics and metals.
Loctite Polyethylene Resistance to heat, chemicals

79A-129-9110 50 cc Used at joint portions subject to
648-50 container
high temperatures.
Used as adhesive or sealant for

LG-1 790-129-9010 200 g Tube gaskets and packing of power
train case, etc.
Used as sealant for various

threads, pipe joints, flanges.
LG-5 790-129-9070 1 kg Can Used as sealant for tapered
Gasket plugs, elbows, nipples of hydrau-
sealant lic piping.
Features: Silicon based, resist-

ance to heat, cold
Used as sealant for flange sur-
LG-6 790-129-9020 200 g Tube
face, tread.
mab Used as sealant for oil pan,
final drive case, etc.
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, featuresr
Ftures: Silicon based, quick hard-

ening type
LG-7 790-129-9070 1g Tube Used as sealant for flywheel
housing, intake manifold, oil an,
Adhesives thermostat housing, etc.
Three bond Used as heat-resisting sealant for

790-129-9090 100 g Tube repairing engine.
1211
Used as lubricant for sliding por-

LM-G 09940-00051 60 g Can
tion (to prevent from squeaking).
Molybdenum
disulphide Used to prevent seizure or scuf-
lubricant fling of the thread when press fit-
LM-P 09940-00040 200 g Tube ting or shrink fitting.
Used as lubricant for linkage,
bearings, etc.
SYG2-400LI General purpose type

SYG2-350LI
G2-LI SYG2-400LI-A Various Various
SYG2-160LI
SYGA-160CNLI
SYG2-400CA Used for normal temperature,

Grease SYG2-350CA light load bearing at places in con-
G2-CA SYG2-400CA-A Various Various tact with water or steam.
SYG2-160CA
SYGA-160CNCA
Molybdenum 400 g Used for places with heavy load

disulphide SYG2-400M (10 per Belows type
lubricant case)
00-11
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUE TABLE (WHEN USING TORQUE WRENCH)
In the case of metric nuts and bolts for which there is no special instruction, tighten to the torque given in
the table below.
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 13.2 1.4 1.35 0.15

8 13 31 3 3.2 0.3
10 17 66 7 6.7 0.7
12 19 113 10 11.5 1
14 22 177 19 18 2
16 24 279 30 28.5 3
18 27 382 39 39 4
20 30 549 59 56 6
22 32 745 83 76 8.5
24 36 927 103 94.5 10.5
27 41 1320 140 135 15

30 46 1720 190 175 20
33 50 2210 240 225 25
36 55 2750 290 280 30
39 60 3290 340 335 35
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
6 10 7.85 1.95 0.8 0.2

8 12 18.6 4.9 1.9 0.5
10 14 40.2 5.9 4.1 0.6
12 17 82.35 7.85 8.4 0.8
Sealing surface
TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

In the case of flared nuts for which there is no
special instruction, tighten to the torque given in
the table below. SAD00483
Thread diameter Width across flat Tightening torque
mm mm Nm kgm
14 19 24.5 4.9 2.5 0.5

18 24 49 19.6 52
22 27 78.5 19.6 82
24 32 137.3 29.4 14 3
30 36 176.5 29.4 18 3
33 41 196.1 49 20 5
36 46 245.2 49 25 5
42 55 294.2 49 30 5
00-12
(23)
TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

In the case of split flange bolts for which there is no special instruction, tighten to the torque given in the
table below.
mm mm Nm kgm
10 14 65.7 0 6.8 6.7 0 0.7

12 17 112 0 9.8 11.5 0 1
16 22 279 0 29 28.5 0 3
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PIPING JOINTS

Unless there are special instructions, tighten the O-ring boss piping joints to the torque below.

Norminal No.
mm mm Nm kgm
02 14 34.3 0 4.9 3.5 0 0.5

03, 04 20 Varies depending 93.1 0 9.8 9.5 0 1
05, 06 24 on type of 142.1 0 19.6 14.5 0 2
10, 12 33 connector. 421.4 0 58.8 43 0 6
14 42 877.1 0 132.3 89.5 0 13.5
TABLE OF TIGHTENING TORQUES FOR O-RING BOSS PLUGS

Unless there are special instructions, tighten the O-ring boss plugs to the torque below.

Norminal No.
mm mm Nm kgm
08 08 14 7.35 0 1.47 0.75 0 0.15

10 10 17 11.27 0 1.47 1.15 0 0.15
12 12 19 17.64 0 1.96 1.8 0 0.2
14 14 22 22.54 0 1.96 2.3 0 0.2
16 16 24 29.4 0 4.9 3 0 0.5
18 18 27 39.2 0 4.9 4 0 0.5
20 20 30 49 0 4.9 5 0 0.5
24 24 32 68.6 0 9.8 701
30 30 32 107.8 0 14.7 11 0 1.5
33 33 n 127.4 0 19.6 13 0 2
36 36 36 151.9 0 24.5 15.5 0 2.5
42 42 n 210.7 0 29.4 21.5 0 3
52 52 n 323.4 0 44.1 33 0 4.5
00-13
TIGHTENING TORQUE FOR 102 ENGINE SERIES

1) BOLT AND NUTS
Use these torques for bolts and nuts (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 10 2 1.02 0.20
8 24 4 2.45 0.41
10 43 6 4.38 0.61
12 77 12 7.85 1.22
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 82 0.81 0.20
8 10 2 1.02 0.20
10 12 2 1.22 0.20
12 24 4 2.45 0.41
14 36 5 3.67 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
Size Torque Torque
Thread Actual Thread O.D. In Aluminum Components In Cast Iron or Steel Components
in in kgm Nm ft-lb kgm Nm ft-lb
1/16 0.32 0.51 5 45 in-lb 1.5 15 10
1/8 0.41 1.5 15 10 2.0 20 15
1/4 0.54 2.0 20 15 2.5 25 20
3/8 0.68 2.5 25 20 3.7 35 25
1/2 0.85 3.7 35 25 5.6 55 40
3/4 1.05 4.6 45 35 7.6 75 55
1 1.32 6.1 60 45 9.7 95 70
1 - 1/4 1.66 7.6 75 55 11.7 115 85
1 - 1/2 1.90 8.7 85 65 13.8 135 100
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque (Nm {kgm}) Taper seal Face seal type

type
Nominal size Width across
of hose flats Nominal thread
Range Target Thread size size - Threads per Root diameter
(mm) inch, Thread series (mm) (Reference)
9
02 19 35 63 {3.5 6.5} 44 {4.5} 14 18UNF 14.3
16
11
22 54 93 {5.5 9.5} 74 {7.5} 16UN 17.5
03 16
24 59 98 {6.0 10.0} 78 {8.0} 18
13
04 27 84 132 {8.5 13.5} 103 {10.5} 22 16UN 20.7
16
05 32 128 186 {13.0 19.0} 157 {16.0} 24 1 14UNS 25.4
3
06 36 177 245 {18.0 25.0} 216 {22.0} 30 1 12UNF 30.3
16
(10) 41 177 245 {18.0 25.0} 216 {22.0} 33
(12) 46 197 294 {20.0 30.0} 245 {25.0} 36
(14) 55 246 343 {25.0 35.0} 294 {30.0} 42
00-14
(23)
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm 2)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal

etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Circuits
Priori-
ty Classi- Charging Ground Starting Lighting Instrument Signal Other
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR n BW RW YR GW LW
2
Color White & Red n White & Black Red & White Rellow & Red Green & White Blue & White
Code WB n BY RB YB GR LR
3
Color White & Black n Black & Yellow Red & Black Yellow & Black Green & Red Blue & Yellow
Code WL n BR RY YG GY LY
4 Auxi-
liary
Color White & Blue n Black & Red Red & Yellow
Yellow &
Green
Green &
Yellow
Blue & Yellow
Code WG n n RG YL GB LB
5
Color White & Green n n Red & Green Yellow & Blue Green & Black Blue & Black
Code n n n RL YW GL n
6
Color n n n Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For details of the
method of using the Conversion Table, see the example given below.
EXAMPLE
Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
A
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line
A
from .
B
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down
B
from .
C
(3) Take the point where the two lines cross as . This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place to the
left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
B
Millimeters to inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
A 50
60
1.969
2.362
2.008
2.402
2.047
2.441
2.087
2.480
2.126
2.520
2.165
2.559
2.205
2.598
2.244
2.638
2.283
2.677
2.323
2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-16
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-17
Liter to U.S. Gallon

1l = 0.2642 U.S. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1l = 0.21997 U.K. Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-18
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-19
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-20
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of
Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of
Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1C = 33.8F
C F C F C F C F
40.4 40 40.0 11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

37.2 35 31.0 11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
34.4 30 22.0 10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
31.7 25 13.0 10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
28.9 20 4.0 9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
28.3 19 2.2 8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

27.8 18 0.4 8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
27.2 17 1.4 7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
26.7 16 3.2 7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
26.1 15 5.0 6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
25.6 14 6.8 6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

25.0 13 8.6 5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
24.4 12 10.4 5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
23.9 11 12.2 4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
23.3 10 14.0 3.9 25 77.0 15.6 0 140.0 35.0 95 203.0
22.8 9 15.8 3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

22.2 8 17.6 2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
21.7 7 19.4 2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
21.1 6 21.2 1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
20.6 5 23.0 1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
20.0 4 24.8 0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

19.4 3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
18.9 2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
18.3 1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22
FOREWORD CAPSCREW MARKINGS AND TORQUE VALUES
CAPSCREW MARKINGS AND TORQUE VALUES

Caution: When replacing capscrews, always use a capscrew of the same measurement and strength
as the capscrew being replaced. Using the wrong capscrews can result in engine damage.
Metric capscrews and nuts are identified by the grade number stamped on the head of the capscrew or
on the surface of the nuts. U.S. Customary capscrews are identified by radial lines stamped on the head
of the capscrew.
The following examples indicate how capscrews are identified:
Metric - M8 1.25 25 U.S. Customary (5/16 18 1-1/2)

M8 1.25 25 5/16 18 1-1/2
Major Distance Length Major Number Length
Thread Between in Thread Threads in
Diameter in Threads in Millimeters Diameter per Inch Inches
Millimeters Millimeters in Inches
NOTES:
1. Always use the torque values listed in the following tables when specific torque values are not avail-
able.
2. Do not use the torque values in place of those specified in other sections of this manual.
3. The torque values in the table are based on the use of lubricated threads.
4. When the ft-lb value is less than 10, give consideration to converting the ft-lb value to in-lb to obtain
a better torque with an in-lb torque wrench. Example: 6 ft-lb equals 72 in-lb.
102 SERIES 00-23

B
Capscrew Markings and torque values - Metric
Commercial Steel Class

8.8 10.9 12.9
Capscrew Head Markings
Body
Size Torque Torque Torque
Diam. Cast Iron Aluminum Cast Iron Aluminum Cast Iron Aluminum
mm kgm Nm ft-lb kgm Nm ft-lb kgm Nm ft-lb kgm Nm ft-lb kgm Nm ft-lb kgm Nm ft-lb
6 0.92 9 5 0.71 7 4 1.2 12 9 0.71 7 4 1.4 14 9 0.71 7 4

7 1.4 14 9 1.1 11 7 1.8 18 14 1.1 11 7 2.3 23 18 1.1 11 7
8 2.5 25 18 1.8 18 14 3.4 33 25 1.8 18 14 4.1 40 29 1.8 18 14
10 4.6 45 33 3.1 30 25 6.1 60 45 3.1 30 25 7.1 70 50 3.1 30 25
12 8.2 80 60 5.6 55 40 10.7 105 75 5.6 55 40 12.7 125 95 5.6 55 40
14 12.7 125 90 9.2 90 65 16.8 165 122 9.2 90 65 19.9 195 145 9.2 90 65
16 18.4 180 130 14.3 140 100 24.5 240 175 14.3 140 100 29.6 290 210 14.2 140 100
18 23.5 230 170 18.4 180 135 32.6 320 240 18.4 180 135 40.8 400 290 18.4 180 135
00-24 102 SERIES

C
Capscrew Markings and torque values - U.S. Customary
SAE grade number 5 8

Capscrew Head Markings
These are all SAE Grade 5 (3) line.
Capscrew Torque - Grade 5 Capscrew Capscrew Torque - Grade 8 Capscrew
Capscrew Body Size Cast Iron Aluminum Cast Iron Aluminum
kgm Nm ft-lb kgm Nm ft-lb kgm Nm ft-lb kgm Nm ft-lb
1/4 - 20 0.92 9 7 0.82 8 6 1.5 15 11 0.82 8 6

- 28 1.2 12 9 0.92 9 7 1.8 18 13 0.92 9 7
5/16 - 18 2.0 20 15 1.6 16 12 3.1 30 22 1.6 16 12
- 24 2.3 23 17 1.9 19 14 3.4 33 24 1.9 19 14
3/8 - 16 4.1 40 30 2.5 25 20 5.6 55 40 2.5 25 20
- 24 4.1 40 30 3.6 35 25 6.1 60 45 3.6 35 25
7/16 - 14 6.1 60 45 4.6 45 35 9.2 90 65 4.6 45 35
- 20 6.6 65 50 5.6 55 40 9.7 95 70 5.6 55 40
1/2 - 13 9.7 95 70 7.6 75 55 13.3 130 95 7.6 75 55
- 20 10.2 100 75 8.2 80 60 15.3 150 110 8.2 80 60
9/16 - 12 13.8 135 100 11.2 110 80 19.4 190 140 11.2 110 80
- 18 15.3 150 110 11.7 115 85 21.4 210 155 11.7 115 85
5/8 - 11 18.4 180 135 15.3 150 110 26 255 190 15.3 150 110
- 18 21.4 210 155 16.3 160 120 29.6 290 215 16.3 160 120
3/4 - 10 33.1 325 240 26 255 190 46.9 460 340 26 255 190
- 16 37.2 365 270 29.1 285 210 52.5 515 380 29.1 285 210
7/8 - 9 50 490 360 38.7 380 280 76 745 550 38.7 380 280
- 14 54 530 390 42.8 420 310 84.1 825 610 42.8 420 310
1-8 73.4 720 530 58.1 570 420 112.2 1100 820 58.1 570 420
- 14 81.6 800 590 66.3 650 480 122.4 1200 890 66.5 650 480
102 SERIES 00-25

C
FOREWORD SYMBOLS
SYMBOLS
The following symbols have been used in this
manual to help communicate the intent of the in-
structions. When one of the symbols appears, it
conveys the meaning defined below:
WARNING - Serious personal injury or ex-

tensive property damage can result if the
warning instructions are not followed.
CAUTION - Minor personal injury can re-

sult or a part, an assembly, or the engine
can be damaged if the caution instructions
are not followed.
Indicates a REMOVAL or DISASSEMBLY

step.
Indicates an INSTALLATION or ASSEM-

BLY step.
INSPECTION is required.
CLEAN the part or assembly.
PERFORM a mechanical or time MEA-

SUREMENT.
LUBRICATE the part or assembly.
Indicates that a WRENCH or TOOL SIZE

will be given.
TIGHTEN to a specific torque.
PERFORM an electrical MEASUREMENT.
Refer to another location in this manual

or another publication for additional in-
formation.
The component weights 23 kg (50 lb) or

more. To avoid personal injury, use a hoist
or get assistance to lift the component.
102 SERIES 00-27

6
FOREWORD ILLUSTRATIONS
ILLUSTRATIONS
The illustrations used in the "Repair Sections" of
this manual are intended to give an example of a
problem, and to show what to look for and where
the problem can be found. Some of the illustra-
tions are 'generic" and will not look exactly like
the engine or parts used in your application.
Some illustrations contain symbols to indicate
and action required, and an acceptable or not ac-
ceptable condition.
The illustrations are intended to show repair or

replacement procedures with the engine "in-chas-
sis". The illustration can differ from your applica-
tion, but the procedure given will be the same.
00-28 102 SERIES

C
GENERAL APPLICABLE MACHINE
APPLICABLE MACHINE
102-1
Serial No. shows for engine serial No.
Engine Serial No. Applicable machine
PC60-7, PC60-7B, PC70-7 Hydraulic excavator

4D102E-1
Mobile crusher
BR100J-1, BR100JG, RG-1 (Gara-Pagos)
PC100-6, PC100-6EXCEL Hydraulic excavator
PC120-6, PC120-6MIGHTY, PC120-6EXCEL Hydraulic excavator
PC128UU-1, PC128US-1, PC128US-2 Hydraulic excavator
PC158US-2 Hydraulic excavator

S4D102E-1
D31E, S, Q, P-20, D31PL, PLL-20, D31P-20A Bulldozer
D37E-5, D37P-5A Bulldozer
WA120-3, WA120-3D Wheel loader
GD305A-3 Motor grader
6D102E-1 D41A-6 Bulldozer
PC200, 200LC-6, PC200, 200LC-6HYPER GX Hydraulic excavator
PC200-6CUSTOM, EXCEL(BKC), PC210, 210LC-6MIGHTY Hydraulic excavator
PC228USL-1, PC228USLC-2 Hydraulic excavator

Mobile crusher
BR200S-1, BR210JG-1 (Gara-Pagos)
CD60RE-1 Crawler carrier

S6D102E-1
D41E, P-6 Bulldozer
WA180-3, WA180-3 (For EU), WA180PT-3, WA180-3 (For CIS) Wheel loader
WA250-3, WA250L-3 (For USA), WA250PT-3 Wheel loader
GD405A-3, GD521A-1E Motor grader
JV100WA-2, JV100WP-2 Vibratory roller
PC220, 220LC-6, PC220-6EXCEL Hydraulic excavator
PC250HD-1, PC250, 250LC-6 Hydraulic excavator

Mobile crusher
SA6D102E-1 BR250RG-1, BR350JG-1 (Gara-Pagos)
WA300L-3 (For USA), WA320-3, WA320-3CUSTOM Wheel loader
DCA-125SSK DENYO generator
01-1-1 102 SERIES

(23)
GENERAL APPLICABLE MACHINE
102-2
Engine Serial No. Applicable machine
D31EX-21, D31PX-21 Bulldozer

SAA4D102E-2
PC160LC-7 Hydraulic excavator

PC200-7, PC200LC-7, PC228US-3, PC228USLC-3, PC270-7,
Hydraulic excavator
PC308USLC-3, PC220-7, PC220LC-7
Mobile crusher
BR120T-1, BR380JG-1 (Gara-Pagos)
WA150-5 Wheel loader
WA200-5 Wheel loader

SAA6D102E-2
WA250-5, WA250PT-5 Wheel loader
WA320-5, WA320PT-5 Wheel loader
GD555-3A, GD555-3C Motor grader
DCA-150ESK Wheel loader
102 SERIES 01-1-2

(21)
GENERAL SPECIFICATIONS
SPECIFICATIONS
102-1
Engine 4D102E-1
Applicable model PC60-7, PC60-7B BR100J, BR100,

PC70-7 JG, RG-1
No. of cylinders - Bore x Stroke mm 4 102 x 120

Total piston displacement {cc} 3.92 {3,920}
Firing order 1342
Overall length mm 976 976

Dimensions
Overall width mm 690 690

Overall height
(excluding exhaust pipe) mm
Overall height
(including exhaust pipe) mm 1,074 1,074
40.5/1,750 40.5/1,750
Flywheel horsepower kW{HP}/rpm {54.3/1,750} {54.3/1,750}
(Net) (Net)
245/1,200 245/1,200
Performance
Max. torque Nm{kgm}/rpm {25.0/1,200} {25.0/1,200}

(Net) (Net)
High idling speed rpm 1,900 2,000 1,900 2,000
Low idling speed rpm 1,000 1,050 1,000 1,050
Min. fuel consumption ratio g/kWh 238 238
{g/HPh} {177} {177}
Dry weight kg 380 380
Fuel injection pump BOSCH PES-A type

Governor BOSCH RSV centrifugal, all speed type
Lubricating oil amount 14.5 14.5

(refil capacity) (14.0) (14.0)
Coolant amount 7.0 (engine only) 7.0 (engine only)
Alternator 24V, 25A 24V, 25A

Starting motor 24V, 4.5kW 24V, 4.5kW
Battery 12V65Ah x 2 12V65Ah x 2
Turbocharger
Air compressor
Others
01-2 102 SERIES

0
Engine S6D102E-1
PC200, 200LC-6 PC200LC-6
Applicable model PC200, 200LC-6 HYPER GX PC200-6 CUSTOM
PC210,210LC-6 MIGHTY, BR200S-1 PC200-6 EXCEL, (BKC)
No. of cylinders - Bore x Stroke mm 6102 x 120

Firing order 153624
Overall length mm 1,361 1,361

Dimensions
Overall width mm 760 760

Overall height
(excluding exhaust pipe) mm
1,301 1,301
Overall height
(including exhaust pipe) mm
99.3/2,000 95.6/2,000
Flywheel horsepower kW{HP}/rpm {133/2,00} {128/2,000}
(Net) (Net)
563/1,350 545/1,350
Performance
Max. torque Nm{kgm}/rpm {57.4/1,350} {55.6/1,350}

(Net) (Net)
High idling speed rpm 2,140 2,260 2,140 2,260
Low idling speed rpm 1,000 1,050 1,000 1,050
Min. fuel consumption ratio g/kWh 228 228
{g/HPh} {170} {170}
Dry weight kg 540 510

Lubricating oil amount 26.3 26.3

(refil capacity) (24.0) (24.0)
Coolant amount 9.0 (engine only) 9.0 (engine only)
Alternator 24V, 35A 24V, 35A

Starting motor 24V, 4.5kW 24V, 4.5kW
Battery 12V110Ah x 2 12V110Ah x 2
Turbocharger HOLSET HX35 type HOLSET HX35 type

Air compressor
Others
01-6 102 SERIES

(23)
S6D102E-1
WA180-3
CD60RE-1 WA180-3 (for EU)
BR200S-1, BR210JG-1 PC228USL-1 PC228USLC-2 D41E, P-6 WA180PT-3
WA180-3 (for CIS)
6 102 x 120
5.88 {5,883}
153624
1,361 1,092 1,092 1,015 1,129
760 705 705 659 789
1,301 975 1,338
1,301 1,301
96.0/2,000 95.6/2,000 95.6/2,000 78.0/2,400 81.0/2,400

{128/2,000} {128/2,000} {128/2,000} {105/2,400} {109/2,400}
(Net) (Net) (Net) (Net) (Net)
545/1,350 545/1,350 545/1,350 461/1,300 417/1,600
{55.6/1,350} {55.6/1,350} {55.6/1,350} {47.0/1,300} {42.5/1,600}
(Net) (Net) (Net) (Net) (Net)
2,140 2,260 2,140 2,260 2,140 2,260 2,650 2,600 2,700
1,000 1,050 1,000 1,050 1,000 1,050 825 750 800

228 228 228 211 218
{170} {170} {170} {157} {163}
510 520 520 530 510
BOSCH PES-A type

BOSCH RSV centrifugal, all speed type
26.3 26.3 26.3 26.8 22.0

(24.0) (24.0) (24.0) (22.8) (21.5)
9.0 (engine only) 9.0 (engine only) 9.0 (engine only) 9.0 (engine only) 9.0 (engine only)
24V, 35A 24V, 35A 24V, 35A 24V, 35A 24V, 35A
24V, 4.5kW 24V, 4.5kW 24V, 4.5kW 24V, 5.5kW 24V, 4.5kW
12V110Ah x 2 12V110Ah x 2 12V110Ah x 2 12V65Ah x 2 12V110Ah x 2
HOLSET HX35 type HOLSET HX35 type HOLSET HX35 type HOLSET HX35 type HOLSET HX35 type

102 SERIES 01-7

(23)
SA6D102E-1
WA320-3 DCA-125SSK
WA320-3 CUSTOM (DENYO generator)
6 102 x 120
5.88 {5,883}
153624
1,131 1,276
710 674
1,041 1,105
114/2,350 115.5/1,800 (60 Hz)

{153/2,350} {154/1,800} (60 Hz)
(Net) (Net)
608/1,600
{62.0/1,600}
(Net)
2,535 2,635 Max. 1,890 (60 Hz)
775 825 750 850

237 226 (60 Hz)
{177} {168} (60 Hz)}
500 520
BOSCH PES-A type

22.0 22
(21.5) (21)
9.0 (engine only) 10.0 (engine only)
24V, 35A 24V, 35A

24V, 4.5kW 24V, 4.5kW
12V140Ah x 2 12V100Ah x 2
HOLSET HX35 type HOLSET HX35 type

(with waste gate) (with waste gate)

With aftercooler
102 SERIES 01-7-6

B
102-2
Engine SAA4D102E-2
Applicable model D31EX-21 D37EX-21 D39EX-21

D31PX-21 D37PX-21 D39PX-21

Firing order 1 342
Overall length mm 920 920 920

Dimensions
Overall width mm 658 658 658

Overall height
(excluding exhaust pipe) mm 947 947 947
Overall height
58.2{78.0}/2,000 63.3{84.9}/2,000 70{94}/2,200

Flywheel horsepower kW{HP}/rpm (Net) (Net) (Net)
Performance
384{39.2}/1,300 412{42}/1,300 434{44.3}/1,300

Max. torque Nm{kgm}/rpm (Net) (Net) (Net)
High idling speed rpm 2,200 50 2,200 50 2,400 50

+50 +50 +50
Low idling speed rpm 800 0 800 0 800 0
Min. fuel consumption ratio g/kWh 224 224 218

{g/HPh} {165} {165} {162}
Dry weight kg 400 400 400

Lubricating oil amount 14 14 14

(refil capacity) (12.5) (12.5) (12.5)
Coolant amount 7.0 (engine only) 7.0 (engine only) 7.0 (engine only)
Alternator 24V, 25A 24V, 25A 24V, 25A

Starting motor 24V, 5.5kW 24V, 5.5kW 24V, 4.5kW
Battery 12V92Ah x 2 12V92Ah x 2 12V88Ah x 2
Turbocharger HOLSET HX25 type HOLSET HX25 type HOLSET HX25 type
Air compressor
Others With air cooled With air cooled With air cooled
aftercooler aftercooler aftercooler
01-7-7 102 SERIES

(19)
SAA4D102E-2
PC160LC-7 WA150-5
4 102 x 120
3.92 {3,920}
1 342
1,013 786
722 715
1,924
1,293
82{110}/2,200 70.8{94.9}/2,000
(Net) (Net)
431{44}/1,500 402{41}/1,300
(Net) (Net)
2,490 50 2,250 50
1,050 50 825 50
212 219
{156} {161}
415 450
BOSCH PES-A type

17.5 14
(16) (12.5)
7.0 (engine only) 7.0 (engine only)
24V, 35A 24V, 35A

24V, 4.5kW 24V, 5.5kW
12V95Ah x 2 12V95Ah x 2
HOLSET HX25 type HOLSET HX25 type

With air cooled With air cooled
aftercooler aftercooler
102 SERIES 01-7-8

(19)
Engine SAA6D102E-2
PC200-7 PC228US-3 PC308USLC-3

Applicable model BR380JG-1
PC200LC-7 PC228USLC-3 PC270-7

Firing order 153624
Overall length mm 1,320 1,320 1,320

Dimensions

Overall height
(excluding exhaust pipe) mm 1,380 1,380 1,443
Overall height
107{143}/1,950 107{143}/1,950 134{180}/2,050

Performance
610{62.2}/1,500 610{62.2}/1,500 718{73.3}/1,500

Max. torque Nm{kgm}/rpm (Net) (Net) (Net)
+70
High idling speed rpm 2,200 30 2,200 30 2,330 _ 30
Low idling speed rpm 1,050 25 1,050 25 1,050 25
Min. fuel consumption ratio g/kWh 203 203 218
{g/HPh} {151} {151} {160}

Lubricating oil amount 26.3 26.3 26.3

(refil capacity) (24.0) (24.0) (24.0)

Turbocharger HOLSET HX35 type HOLSET HX35 type HOLSET HX35 type
Air compressor
With air cooled With air cooled With air cooled
Others
01-7-9 102 SERIES

(18)
SAA6D102E-2
WA200-5 WA250-5 WA320-5 GD555-3A

BR120T-1 WA200PT-5 WA250PT-5 WA320PT-5 GD555-3C
6 102 x 120
5.88 {5,883}
1 5 3 6 2 4
1,210 1,069 1,069 1,069 1,070
750 785 785 785 747
1,380 1,483 1,483 1,483 1,123
141{189}/2,050 95.2{127.7}/2,000 104.1{139.5}/2,000 127{170}/2,000 124.5{167}/2,000

(Gross) (Gross) (Gross) (Gross) (Gross)
740{75.7}/1,500 586{59.8}/1,400 627{64}/1,400 672{68.5}/1,500 743{75.7}/1,500

(Gross) (Gross) (Gross) (Gross) (Gross)
2,330 50 2,250 50 2,250 50 2,250 50 2,230 50
1,050 25 825 50 825 50 900 25 900 50
203 224 224 224 227

{151} {167} {167} {167}
550 580 580 600 550
BOSCH PES-A type

26.3 21.8 21.8 21.8 26.3

(24.0) (19.5) (19.5) (19.5) (24.0)
9.0 (engine only) 9.0 (engine only) 9.0 (engine only) 9.0 (engine only) 9.0 (engine only)
24V, 35A 24V, 35A 24V, 35A 24V, 60A 24V, 35A
24V, 4.5kW 24V, 4.5kW 24V, 4.5kW 24V, 5.5kW 24V, 5.5kW
12V120Ah x 2 12V120Ah x 2 12V120Ah x 2 12V120Ah x 2 12V140Ah x 2
HOLSET HX35 type HOLSET HX35 type HOLSET HX35 type HOLSET HX35 type HOLSET HX35 type

With air cooled With air cooled With air cooled With air cooled With air cooled
aftercooler aftercooler aftercooler aftercooler aftercooler
102 SERIES 01-7-10

(20)
Engine SAA6D102E-2
Applicable model PC308USLC-3 PC220-7 DCA-150ESK

PC220LC-7 (DENYO generator)

Firing order 153624
Overall length mm 1,320 1,320 1,360

Dimensions

Overall height
(excluding exhaust pipe) mm 1,383 1.240
Overall height
(including exhaust pipe) mm 1,443
113{151}/1,500(50Hz)
134{180}/2,050 125{168}/2,000 135{180}/1,800(60Hz)
Performance
718{73.3}/1,500 684{69.8}/1,500
Max. torque Nm{kgm}/rpm (Net) (Net)
+70 +80 Max.1,580(50Hz)
High idling speed rpm 2,330 _ 30 2,260 _ 20 Max.1,890(60Hz)
Low idling speed rpm 1,050 25 1,050 25 800 50
Min. fuel consumption ratio g/kWh 218 218 218{163}(50Hz)
{g/HPh} {163} {163} 224{167}(60Hz)

Lubricating oil amount 26.3 26.3 22

(refil capacity) (24.0) (24.0) (21.0)

Turbocharger HOLSET HX35 type HOLSET HX35 type MHI TE06H

Air compressor
With air cooled With air cooled With air cooled
Others
01-7-11 102 SERIES

(21)
GENERAL GENERAL ASSEMBLY DRAWING
GENERAL ASSEMBLY DRAWING

4D102E-1 (PC60-7)
LEFT-HAND VIEW
Depending on the applicable model, the view may be different from the drawing.
01-8 102 SERIES

B
GENERAL ENGINE PERFORMANCE CURVE
ENGINE PERFORMANCE CURVE

102E-1
Engine Serial No. Applicable machine Page
4D102E-1 PC60-7, PC60-7B, PC70-7 01-22
PC100-6, PC100-6L-6 01-22-1
PC120-6 EXCEL 01-22-2
PC120-6, PC130-6 01-22-3
PC128UU-1 01-22-4
PC100, 100L-6, PC100-6 EXCEL 01-23
PC120-6, PC130-6 MIGHTY 01-24
PC120-6 EXCEL 01-25

S4D102E-1
PC128UU-1 01-26
PC128US-1, PC128US-2 01-27
PC158US--2 01-27-1
WA120-3, WA120-3D 01-28
D31E, S, Q, P, PL, PLL-20, D31P-20A 01-29
D37E-5, D37P-5A 01-30
GD305A-3 01-31
PC200, 200LC-6, PC200, 200LC-6 HYPER GX, 01-32
PC210, 210LC-6 MIGHTY, BR200S-1
PC200LC-6 EXCEL, PC200-6 CUSTOM, 01-33
PC228UU, 228USLC-1, 228USLC-2, CD60RE-1
WA180-3, WA180-3 (For EU), WA180PT-3, WA180-3 (For CIS) 01-34
S6D102E-1 WA250-3, WA250PT-3 01-34-1
JV100WA-2, JV100WP-2 01-34-2
GD521A-1E 01-34-3
PC220, 220LC-6, PC250HD-1, PC250, 250LC-6 01-34-5
SA6D102E-1 PC220, 220LC-6 EXCEL 01-34-6
WA300L-3 (For USA), WA320-3, WA320-3 CUSTOM 01-34-8
01-21-1 102 SERIES

(23)
102E-2
Engine Serial No. Applicable machine Page
D31EX, PX-21 01-34-18
D37EX, PX-21 01-34-19

SAA4D102E-2
D39EX, PX-21 01-34-20
PC160LC-7 01-34-21
PC200-7, PC200LC-7, PC228US, USLC-3 01-34-31
BR120T-1 01-34-32
PC270-7, PC308USLC-3, BR380JG-1 01-34-33
WA150-5 01-34-22
SAA6D102E-2 WA200-5, WA200PT-5 01-34-37
WA250-5, WA250PT-5 01-34-34
WA320-5, WA320PT-5 01-34-35
GD555-3A, GD555-3C 01-34-36
PC220-7, PC220LC-7 01-34-38
102 SERIES 01-21-2

(20)
S6D102E-1 (WA180-3, WA180-3 (FOR EU), WA180PT-3, WA180-3 (FOR CIS))

Flywheel horsepower : 81.0 kW {108 HP} /2,400 rpm (Net)
Maximum torque : 417 Nm {42.5 kgm} /1,600 rpm (Net)
01-34 102 SERIES

(23)
SAA4D102E-2 (D31EX-21, D31PX-21)

Flywheel horsepower : 58.2 kW {78 HP} /2,000 rpm (Net)
01-34-18 102 SERIES

(19)
SAA4D102E-2 (D37EX-21, D37PX-21)

Flywheel horsepower : 63.3 kW {84.9 HP} /2,000 rpm (Net)
Maximum torque : 412 Nm {42 kgm} /1,300 rpm (Net)
102 SERIES 01-34-19

(19)
SAA4D102E-2 (D39EX-21, D39PX-21)

Flywheel horsepower : 70 kW {94 HP} /2,200 rpm (Net)
01-34-20 102 SERIES

0
SAA4D102E-2 (PC160LC-7)
Flywheel horsepower : 82.4 kW {110.5 HP} /2,200 rpm (Net)
Maximum torque : 431 Nm {44 kgm} /1,500 rpm (Net)
102 SERIES 01-34-21

C
SAA4D102E-2 (WA150-5)
Flywheel horsepower : 74.2 kW {99.5 HP} /2,000 rpm (Gross)
Maximum torque : 408 Nm {41.6 kgm} /1,300 rpm (Gross)
01-34-22 102 SERIES

(19)
SAA6D102E-2 (PC200-7, PC200LC-7, PC228US-3, PC228USLC-3)

102 SERIES 01-34-31

C
SAA6D102E-2 (BR120T-1)
Flywheel horsepower : 141 kW {189 HP} /2,050 rpm (Gross)
01-34-32 102 SERIES

C
SAA6D102E-2 (PC270-7, PC308USLC-3, BR380JG-1)

102 SERIES 01-34-33

(18)
SAA6D102E-2 (WA250-5, WA250PT-5)

Maximum torque : 627 Nm {64 kgm} /1,400 rpm (Gross)
01-34-34 102 SERIES

(19)
SAA6D102E-2 (WA320-5, WA320PT-5)

Flywheel horsepower : 127 kW {170 HP} /2,000 rpm (Gross)
102 SERIES 01-34-35

(20)
SAA6D102E-2 (WA200-5, WA200PT-5)

102 SERIES 01-34-37

(19)
SAA6D102E-2 (PC220-7, PC220LC-7)

01-34-38 102 SERIES

(19)
STRUCTURE AND FUNCTION TURBOCHARGER
Lubrication of turbocharger (engine with turbocharger)
1. Oil supply pipe

2. Oil drain pipe
The oil to the turbocharger is filtered, cooled, and

pressurized, then passes from the filter head and
goes through the oil supply pipe (1) to the turbo-
charger. The oil then passes through the oil drain
pipe (2) connected to the bottom of the turbo-
charger housing, goes through the block fitting and
returns to the oil pan.
102 SERIES 11-9

C
STRUCTURE AND FUNCTION CYLINDER HEAD
CYLINDER HEAD
(S)4D102E-1
SAA4D102E-2
Depending on the machine model, the actual
component may be different from the diagram.
1. Cylinder head 4. Head bolt Head cover

2. Oil filler cap 5. Nozzle holder Float mount type
3. Head cover 6. Gasket
11-10 102 SERIES

B
STRUCTURE AND FUNCTION CYLINDER BLOCK
CYLINDER BLOCK
(S)4D102E-1
SAA4D102E-2
1. Main bearing cap a. Piston cooling nozzle

2. Main bearing cap bolt b. Thrust face (top face only, No. 4 journal)
3. Cylinder block
4. Cam bushing (journal No. 1)
5. Dowel ring (main bearing cap positioner)
11-14 102 SERIES

(17)
STRUCTURE AND FUNCTION CYLINDER BLOCK
(S)6D102E-1, SA6D102E-1
SAA6D102E-2
Depending on the machine model, the actual com-
ponent may be different from the diagram.
1. Main bearing cap a. Piston cooling nozzle

2. Main bearing cap bolt b. Thrust face (top face only, No. 6 journal)
3. Cylinder block
4. Cam bushing (journal No. 1)
5. Dowel ring (main bearing cap positioner)
6. Cam follower cover
7. Breather hose
11-15-1 102 SERIES

(17)
STRUCTURE AND FUNCTION MAIN MOVING PARTS
MAIN MOVING PARTS

(S)4D102E-1
SAA4D102E-2
1. Crankshaft 11. Second ring a: Ring carrier

2. Crankshaft gear 12. Oil ring b: Toroidal
(No. of teeth: 36) 13. Connecting rod cap c: Re-entrant
3. Main bearing 14. Main cap d: Piston cooling nozzle
4. Connecting rod bearing 15. Main cap bolt
5. Connecting rod 16. Connecting rod cap bolt
6. Cylinder block (no lining) 17. Thrust bearing
7. Piston (top face only No. 4 journal)
8. Connecting rod bushing 18. Pin
9. Piston pin 19. Crankshaft pulley
10. Top ring
11-18 102 SERIES

(17)
STRUCTURE AND FUNCTION MAIN MOVING PARTS
(S)6D102E-1, SA6D102E-1
SAA6D102E-2
1. Crankshaft 11. Second ring a: Ring carrier

2. Crankshaft gear 12. Oil ring b: Toroidal
(No. of teeth: 36) 13. Connecting rod cap c: Re-entrant
3. Main bearing 14. Main cap d: Piston cooling nozzle
4. Connecting rod bearing 15. Main cap bolt
5. Connecting rod 16. Connecting rod cap bolt
6. Cylinder block (no lining) 17. Thrust bearing
7. Piston (top face only No. 6 journal)
8. Connecting rod bushing 18. Pin
9. Piston pin 19. Crankshaft pulley
10. Top ring
11-19-1 102 SERIES

(17)
STRUCTURE AND FUNCTION VALVE MECHANISM
Valve timing
Valve lift Valve angle (Open, closed)

S4D102E-1 S4D102E-1
4D102E-1 S6D102E-1 4D102E-1 S6D102E-1
SA6D102E-1 SA6D102E-1
6D102E-1 6D102E-1
SAA4D102E-2 SAA4D102E-2
Intake 10.6 mm 9.9 mm a 10 11.5
Intake
Exhaust 11.7 mm 11.7 mm b 30 9.5
c 53 53
Exhaust
d 19 19
12. Spring seat

13. Valve cotter
14. Valve spring
15. Valve stem seal (intake, exhaust)
16. Rocker arm
102 SERIES 11-27

(17)
STRUCTURE AND FUNCTION OIL PAN
S6D102E-1 (For CIS)

1. Underplate
2. Oil pan
3. Drain plug
4. Drain hose
5. Oil pan heater
102 SERIES 11-29-2

(23)
STRUCTURE AND FUNCTION LUBRICATION SYSTEM DIAGRAM
Oil cooler
On this engine, a full-flow plate shape oil cooler
(3) is used. The oil flows through the passage cast
in the cooler cover and goes to the element, where
it is cooled in the element by the engine cooling
water flowing through the plate. On the 4-cycle
engine, element (A) with five plates is used, and
on the 6-cycle engine, element (B) with seven plates
is used.
There is a difference in the resistance and pump
volume of the plates, so there is no interchange-
ability in the oil cooler components between the
two engines. If the correct component is not used,
it will cause high temperature, low temperature,
or the formation of varnish or sludge.
Caution: Up to 10/21/86, a 9-plate oil cooler element
was used for the 6-cylinder engine.
Oil filter
After the oil is cooled, it is sent to full-flow oil filter
(4). The filter on the 6-cylinder engine is slightly
longer than the filter on the 4-cylinder engine.
Caution: Even if the 6-cylinder engine filter is
used on the 4-cylinder engine, there
will be no increase in the replace-
ment interval. Do not use a 4-cylin-
der engine filter on the 6-cylinder
engine under any circumstances.
This will cause a drop in the filtering
capacity and will cause an increase
in clogging.
Oil cooler bypass valve

Bypass valve (5) is installed in the oil cooler cover
to allow the oil to flow through the bypass when
the filter is clogged. The valve is designed so that
when the filter is clogged and the drop in pressure
on both sides of the filter exceeds 1.4
kg/cm2 (138 kPa) (20 psi), the valve opens and al-
lows the oil to flow to the engine. When the filter
is clogged, the oil pressure drops within 0.6 kg/cm2
(60 kPa) (10 psi) lower than the normal operating
oil pressure. This can be observed on the oil pres-
sure gauge.
To avoid this condition, it is best to replace the fil-
ter at the drain interval given in the Operation and
Maintenance Manual, Bulletin No. 3810205-10.
102 SERIES 11-35

C
STRUCTURE AND FUNCTION LUBRICATION SYSTEM DIAGRAM
Lubrication of output power related equipment
11-36 102 SERIES

C
STRUCTURE AND FUNCTION FUEL SYSTEM DIAGRAM
FUEL SYSTEM DIAGRAM

(S)4D102E-1

1. Fuel tank 5. Fuel filter

2. Gauze filter 6. Overflow valve
3. Priming pump 7. Fuel injection pump
4. Feed pump 8. Fuel injection nozzle
102 SERIES 11-43

B
(S)4D102E-1, SAA4D102E-2
1. Fuel tank 5. Fuel filter

2. Gauze filter 6. Overflow valve
3. Priming pump 7. Fuel injection pump
4. Feed pump 8. Fuel injection nozzle
11-44 102 SERIES

C
Components of fuel system and flow of fuel

The diagram below shows the components of the fuel system.
1. Fuel from fuel tank 8. Robot Bosch P7100 injection pump

2. Pre-filter or screen 8A. Robot Bosch rotary injection pump
3. Lift pump 9. Fuel drain manifold
4. Fuel/water separator 10. High pressure line
5. Fuel filter 11. Robot Bosch 17 mm nozzle, hole-type in-
6. Low pressure fuel supply line jector
7. Turbo boost control line 12. Fuel returns to fuel tank
102 SERIES 11-47

C
STRUCTURE AND FUNCTION FUEL INJECTION PUMP
FUEL INJECTION PUMP

(S)4D102E-1
SAA4D102E-2
1. Oil tube 10. Fuel injection pipe (No. 3)

2. Feed pump 11. Fuel injection pipe (No. 4)
3. Drive shaft 12. Spill tube
4. Fuel pump drive gear (No. of teeth: 72) 13. Overflow valve
5. Priming pump 14. Fuel injection pump (boost compensator)
6. Priming pump body 15. Fuel injection pump (governor)
7. Fuel filter 16. Boost compensator tube
8. Fuel injection pipe (No. 1) 17. Pressure piping for boost compensator cancel
9. Fuel injection pipe (No. 2) 18. Timing lock
11-48 102 SERIES

B
STRUCTURE AND FUNCTION FAN DRIVE
102E-2
All the pulleys are for polyvinyl V-belts.
Outside diameter of pulley (mm)

Engine Machine model a b c d e
(Alternator) (Fan) (Tension) (Crankshaft) (Water pump)
D31EX-21
D31PX-21
D37EX-21
D37PX-21 80 209 73.9 173 88
D39EX-21
D39PX-21
SAA4D102E-2
PC160LC-7 77.5 195 73.9 173 88
(1)
WA150-5 77.5 157 73.9 173 88
PC200-7
77.5 182 73.9 173 88
PC200LC-7
PC228US-3
77.5 204 73.9 173 88
PC228USLC-3
(1)
BR120T-1 77.5 177 73.9 173 88
BR380JG-1 77.5 172 73.9 173 88
SAA6D102E-2
WA200-5
WA200PT-5 (1)
WA250-5 77.5 157 73.9 173 88
WA250PT-5
WA320-5, WA320PT-5
GD555-3A (1)
80 157 73.9 173 88
GD555-3C
PC220-7
PC220LC-7 77.5 172 73.9 173 88
PC270-7
PC308USLC-3
DCA-150ESK
80 181.8 73.9 174.4 88
(DENYO generator)
1. Engine without fan.
102 SERIES 11-59-2

(21)
STRUCTURE AND FUNCTION FAN DRIVE
1. Water pump A. From radiator

2. Alternator B. Direction of air flow
3. Auto tension a, b, c, d, e: Outside diameter of pulley
4. Fan (inclined axial flow fan or axial f: Hole for square wrench
flow fan)
5. Fan hub
6. Fan bracket
7. Crankshaft pulley
8. Accessory drive pulley
9. Poly V-belt
10. Fan drive V-belt
Pulley diameter (mm)

Engine Model a b c d e
(Alternator) (Fan) (Accessory*) (Crankshaft) (Water pump)
PC220-6 77.5 185 157 185 (V-belt) 88

SA6D102E-1 (Poly V-belt) (Poly V-
PC220-6 EXCEL (Poly V-belt) (V-belt) (V-belt) 173 belt) (Poly V-belt)
PC200-6 77.5 185 157 165 (V-belt) 88

S6D102E-1 (Poly V-belt)
PC200-6 EXCEL (Poly V-belt) (V-belt) 173 (Poly V- (Poly V-belt)
(V-belt) belt)
11-59-3 102 SERIES

B
STRUCTURE AND FUNCTION AIR COMPRESSOR
AIR COMPRESSOR
Outline of air compressor system Caution: The cylinder head and unload compo-
Normally, the compressed air system consists of nents on the Holset SS161B air compres-
a gear driven air compressor, air governor, air sor are used for various engines, so
tank, and piping. maintenance can be carried out without
removing the air compressor. In this
manual, the explanation of the methods
for maintenance of the air compressor
unloader components are given for the
condition when the compressor is still
installed to the engine. When carrying
out maintenance on components or
other parts inside the air compressor, the
compressor must be removed from the
engine. For details of the procedure for
disassembly and assembly of the air
compressor, see SS192B shop manual,
Bulletin No. 3810433.
The Holset SS191 air compressor (1) is an engine The Holset SS296 air compressor is an engine
driven piston type compressor which supplies driven piston type compressor which supplies
compressed air to drive the air operated compo- compressed air to drive the air operated compo-
nents. The compressor operates continuously, nents. The compressor operates continuously,
but it has two operating modes (load and un- but it has two operating modes (load and un-
load). The operating mode is controlled by a load). The operating mode is controlled by a
pressure operated governor and compressor un- pressure operated governor and compressor un-
loading assembly. When the air line reaches the loading assembly.
set pressure, the governor (2) sends an air signal
to the air compressor unloader assembly and sets The SS296 air compressor used on the B series
the unloader valve with the compressor suc- engine uses an (E type) unloader. The economy
tion valve open, so this stops the flow of com- (E type) unloader system is designed to reduce
pressed air into the air line. It uses the air in the the pumping loss and engine boost pressure loss
air line, so the pressure goes down. When the air by the compressor intake valve when operating
pressure reaches the set pressure, the governor in the unloader mode.
exhausts the air signal sent to the compressor
unloader assembly, so the compressor again When the air line reaches the set pressure, the
starts to send compressed air to the air line. governor sends an air signal to the air compres-
sor unloader assembly and sets the unloader
There are two types of cooling for the air com- valve with the compressor suction valve open, so
pressor: air cooled and water cooled. The only this stops the flow of compressed air into the air
difference between these two types of cooling is line.
that modification has been made to the cylinder
head to include a water passage. Caution: The pressure inside the system must be
maintained by keeping the discharge
There are two types of installation for the air com- valve closed at the outlet port end of the
pressor: one type is installed to the power steer- discharge valve.
ing pump housing, and the other is not installed
to it. It uses the air in the air line, so the pressure goes
down. When the air pressure reaches the set pres-
On the 102 series engine, it is possible to use sure, the governor exhausts the air signal sent to
other brands of compressor. The troubleshoot- the compressor unloader assembly, so the com-
ing procedures for these air compressors is very pressor again starts to send compressed air to
similar to the Holset SS191B. For details of the the air line.
torque value and repair methods, see the manual
issued by the air compressor manufacturer.
11-60 102 SERIES

C
STRUCTURE AND FUNCTION AIR COMPRESSOR
Caution:Machines which use a Holset (E

type) air compressor and are
equipped with a dehumidifier to
carry out ventilation during opera-
tion of the unload compressor must
have an air compressor valve in-
stalled to prevent excessive oil con-
sumption.
If it is impossible to maintain the air line pres-

sure with the exhaust valve during unload opera-
tions, air is sent out from the compressor cylin-
der to lower the pressure (back pressure) inside
the cylinder. If the seal of the intake valve in the
unloader cap is loosened and the exhaust valve
becomes a one way pressure starting valve, air
will stop flowing to the cylinder. When the com-
pressor cylinder pressure becomes lower than the
crankcase pressure, oil is sucked in from the pis-
ton ring and sent to the oil line.
102 SERIES 11-61

STRUCTURE AND FUNCTION FLOW DIAGRAMS-COMPRESSED AIR SYSTEM
FLOW DIAGRAMS-COMPRESSED AIR SYSTEM

With air dryer
Without air dryer
1. Compressor
2. Governor
3. Air dryer
4. Check valve
(normally built into dryer)
5. Reservoir (wet tank)
11-62 102 SERIES

C
STRUCTURE AND FUNCTION FLOW DIAGRAMS-COMPRESSED AIR SYSTEM
E type Holset SS296BE with humidifier
1. Compressor
2. Governor
3. Air conditioner valve
4. Air dryer
5. Check valve (normally built into dryer)
6. Reservoir (wet tank)
7. Check valve
102 SERIES 11-63

C
STRUCTURE AND FUNCTION ALTERNATOR
ALTERNATOR
Alternator with built-in regulator (25A, 30A)
1. Alternator 6. Internal electric circuit diagram

2. Alternator pulley 6A. Field coil
3. Terminal R 6B. Primary energized resistance
4. Terminal B 6C. Regulator
5. Terminal E
Pulley
Engine Machine model Type Specification Weight
Outside (kg)
No. of steps diameter (mm)
PC60-7, PC70-7 Nikko Denki, Polyethylene V-
4D102E-1 open type 24V, 25A 80 6.5
PC75UU-3 belt, 8 grooves
PC100-6, PC120-6 Nikko Denki, Polyethylene V-
S4D102E-1 PC158US-2 open type 24V, 25A belt, 8 grooves 80 6.5
PC228US-1 Nikko Denki, Polyethylene V-

S6D102E-1 JV100-2 open type 24V, 25A belt, 8 grooves 80 6.5
WA300-3
Nikko Denki, Polyethylene V-
SA6D102E-1 DCA-125SSK 24V, 30A belt, 8 grooves 80 6.5
(DENYO generator) open type
SAA6D102E-2 DCA-150ESK Nikko Denki, Polyethylene V- 6.5

24V, 25A belt, 8 grooves 80
(DENYO generator) open type
11-64 102 SERIES

(21)
Alternator with built-in regulator (25A)


5. Terminal E
Pulley
Outside (kg)
D31EX-21
D31PX-21
D37EX-21
SAA4D102E-2 D37PX-21 Nikko Denki, Polyethylene V-
open type 24V, 25A 80 6.5
D39EX-21 belt, 8 grooves
D39PX-21
PC128US-2
PC138US-2
102 SERIES 11-64-1

(19)


5. Terminal E
Pulley
Outside (kg)
WA100-3 Nikko Denki, Polyethylene V-
S4D102E-1 24V, 35A 80 8.0
GD305A-3, GD355A-3 open type belt, 8 grooves
GD405A-3 Nikko Denki, Polyethylene V-
S6D102E-1 open type 24V, 35A belt, 8 grooves 80 8.0
GD505A-3A
SA6D102E-1 WA300-3 open type 24V, 35A belt, 8 grooves 80 8.0
D31EX-21, D31PX-21 Nikko Denki, Polyethylene V-

SAA4D102E-2 D37EX-21, D37PX-21 open type 24V, 35A belt, 8 grooves 80 8.0
D39EX-21, D39PX-21
11-64-2 102 SERIES

(19)

1. Alternator 5. Terminal IG 6C. Load of L terminal

2. Alternator pulley 6. Internal connection diagram 6D. Key switch
3. Terminal B 6A. Alternator assembly 6E. Battery
4. Terminal L 6B. Regulator
Pulley
Outside (kg)
PC200-6 Nihon denso, 24V, 35A Polyethylene V-
S6D102E-1 open type belt, 8 grooves 77.5 4.7
PC200-6 EXCEL
Nihon denso, Polyethylene V-
SA6D102E-1 PC220-6 open type 24V, 35A belt, 8 grooves 77.5 4.7
SAA4D102E-2 WA150-5 open type 24V, 35A belt, 8 grooves 77.5 4.7
PC200-7 (26282900 26328689)
PC200LC-7 (26282900 26328689)
PC220-7 (26287717 26335033)
PC220LC-7 (26287717 26335033)
PC228US-3 (26274903 26307087)
PC228USLC-3
SAA6D102E-2 (26274903 26307087) Nihon denso, 24V, 35A Polyethylene V- 77.5 4.7
PC270-7 open type belt, 8 grooves
GD555-3A, 3C
BR120T-1
BR380JG-1
WA200-5, WA200PT-5
WA250-5, WA250PT-5
102 SERIES 11-64-3

(19)

1. Alternator 4B. Regulator

2. Alternator pulley 4C. Load of L terminal
3. Terminal B 4D. Key switch
4. Internal connection diagram 4E. Battery
4A. Alternator assembly
Pulley
Outside (kg)
SAA4D102E-2 PC160LC-7 Nihon denso, Polyethylene V-

WA150-5 open type 24V, 35A belt, 8 grooves 77.5 4.7
PC200-7 (26328690 and up)
PC200LC-7
(26328690 and up)
PC228US-3
(26307088 and up)
PC228USLC-3 Nihon denso, Polyethylene V-
SAA6D102E-2 (26307088 and up) open type 24V, 35A 77.5 4.7
belt, 8 grooves
PC220-7 (26335034 and up)
PC220LC-7
(26335034 and up)
WA200-5, WA200PT-5
WA250-5, WA250PT-5
11-64-4 102 SERIES

(19)


5. Terminal E
Pulley
Outside (kg)
S6D102E-1 WA180-3 (For CIS) open type 24V, 50A belt, 2 grooves 85 11
102 SERIES 11-64-5

(23)

1. Alternator 5. Terminal IG 6C. Load of L terminal

2. Alternator pulley 6. Internal connection diagram 6D. Key switch
3. Terminal B 6A. Alternator assembly 6E. Battery
4. Terminal L 6B. Regulator
Pulley
Outside (kg)
S4D102E-1 PW128UU-1 open type 24V, 60A belt, 8 grooves 77.5 6.3
PC228UU-1 Nihon denso, Polyethylene V-
S6D102E-1 (tunnel specification) open type 24V, 60A belt, 8 grooves 77.5 6.3
SAA4D102E-2 WA150-5 open type 24V, 60A belt, 8 grooves 77.5 6.3
PC200-7 (26282900 26328689)
PC200LC-7 (26282900 26328689)
PC228US-3 (26274903 26307087)
PC228USLC-3
(26274903 26307087)
(tunnel specification) Nihon denso, Polyethylene V-
SAA6D102E-2 PC220-7 (26287717 26335033) open type 24V, 60A belt, 8 grooves 77.5 6.3
PC220LC-7 (26287717 26335033)
PC270-7
PC308USLC-3
WA200-5, WA200PT-5
WA250-5, WA250PT-5
11-64-6 102 SERIES

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1. Alternator 4B. Regulator

2. Alternator pulley 4C. Load of L terminal
3. Terminal B 4D. Key switch
4. Internal connection diagram 4E. Battery
4A. Alternator assembly
Pulley
Outside (kg)
SAA4D102E-2 WA150-5
PC200-7 (26328690 and up)
PC200LC-7
(26328690 and up)
PC220-7 (26335034 and up)
PC220LC-7
(26335034 and up) Nihon denso, Polyethylene V- 6.3
SAA6D102E-2 PC228US-3 open type 24V, 60A belt, 8 grooves 77.5
(26307088 and up)
PC228USLC-3
(26307088 and up)
(tunnel specification)
WA200-5, WA200PT-5
WA250-5, WA250PT-5
WA320-5, WA320PT-5
102 SERIES 11-64-7

(23)
STRUCTURE AND FUNCTION STARTING MOTOR
STARTING MOTOR
With separate safety relay (4.5 kW)
1. Pinion gear
2. Magnetic switch
3. Starting motor (yoke)
4. Internal connection diagram
4A. Battery
4B. Starting switch
4C. To alternator R
4D. Safety relay
4E. Starting motor
4F. Terminal B
4G. Terminal C
Engine Machine model Type Specification No. of pinion teeth Weight (kg)
4D102E-1 Nikko Denki,
All model sealed type 24V, 4.5kw 10 8.7
S4D102E-1
EG125BS-2 Nikko Denki,
SA6D102E-1 24V, 4.5kw 10 8.7
DCA-125SSK (DENYO generator) sealed type
102 SERIES 11-65

(15)
With separate safety relay (4.5 kW) Depending on the machine model, the actual
1. Pinion gear 5. Jump start protective cover 8B. Starting switch

2. Magnetic switch 6. 50 (Terminal C) 8C. Battery
3. Starting motor assembly 7. 30 (Terminal B) 8D. 30 (Terminal B)
4. Warning plate 8. Internal connection diagram 8E. 50 (Terminal C)
(For jump start prohibition) 8A. Relay
S4D102E-1 PC120 Nihon denso, 24V, 4.5kW 8.4

tunnel specification sealed type 10
S6D102E-1 PC200-6 Nihon denso, 24V, 4.5kW 10 8.4

SA6D102E-1 GD405A-3 sealed type
GD505A-3A, WA180-3 (for CIS)
D39EX-21 Nihon denso,
SAA4D102E-2 D39PX-21 24V, 4.5kW 10 8.4
sealed type
PC160LC-7
PC200-7
PC200LC-7
PC220-7
PC220LC-7 Nihon denso,
PC228US-3 24V, 4.5kW 10 8.4
sealed type
SAA6D102E-2 PC228USLC-3
PC270-7
WA200-5, WA200PT-5
WA250-5, WA250PT-5
BR120T-1
DCA-150ESK (DENYO generator)
11-66 102 SERIES

(23)
With separate safety relay (5.5 kW)

fl Depending on the machine model, the actual
1. Pinion gear 8. Internal connection diagram

2. Magnetic switch 8A. Relay
3. Starting motor assembly 8B. Starting switch
4. Warning plate (For jump start prohibition) 8C. Battery
5. Jump start protective cover 8D. 30 (Terminal B)
6. 50 (Terminal C) 8E. 50 (Terminal C)
7. 30 (Terminal B)
D31EX-21, D31PX-21
SAA4D102E-2 D37EX-21, D37PX-21 Nihon denso,
24V, 5.5kW 10 10.5
D39EX-21, D39PX-21 sealed type
WA150-5
PC220-6 Nihon denso,
SA6D102E-1 24V, 5.5kW 10 10.5
WA300-3 sealed type
PC200-7, PC200LC-7
PC220-7
PC228US-3, PC228USLC-3
PC270-7 Nihon denso,
SAA6D102E-2 BR120T-1, BR380JG-1 sealed type 24V, 5.5kW 10 10.5
WA320-5, WA320PT-5
GD555-3A, 3C
PC308USLC-3
102 SERIES 11-66-1

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STRUCTURE AND FUNCTION STARTING AID
STARTING AID
Electrical heater (electrical intake air heater)
1. Heater coil
2. Housing
3. Internal connection diagram
Electrical heater (electrical intake air heater)

Rated current: 100 A/22 V
Coolant heater
Specification
230 V, 1.0 kW
102 SERIES 11-67

(23)
TESTING AND ADJUSTING FUEL INJECTION PUMP CALIBRATION DATA
FUEL INJECTION PUMP CALIBRATION DATA

102-1
Engine model Pump assembly No. Engine serial No. Applicable machine Page
6731-71-1110 PC60-7, 7B, PC70-7, BR100JG, RG-1 12-50

4D102E-1
6732-71-1120 PC100, 100L-6, PC100-6 EXCEL 12-50-1

6732-71-1121 PC100, 100L-6 12-50-2
6732-71-1122 PC100,100L-6 m/c, PC100-6 EXCEL 12-50-3
6732-71-1130 PC120-6, PC130-6 MIGHTY 12-50-4
6732-71-1131
PC120-6, PC130-6 MIGHTY 12-50-5
6732-71-1132
6732-71-1141 WA120-3 12-50-13
6732-71-1150 PC128UU-1 12-50-8
6732-71-1151 PC128UU-1 12-50-40
6732-71-1190 PC120-6 EXCEL 12-50-6
S4D102E-1
6732-71-1191 PC120-6 EXCEL 12-50-7
D31E, S, Q, P-20, D31PL, PLL-20
6732-71-1230 12-50-11
D31P-20A
6732-71-1240 D37E-5, D37P-5A 12-50-12
6732-71-1260 GD305A-3 12-50-15
6732-71-1361 PC128US-2 12-50-10
6732-71-1380
PC128US-1 12-50-9
6732-71-1381
6732-71-1390 WA120-3D 12-50-14
6732-71-1420 PC158US-2 12-50-41
6735-71-1120 D41E, P-6 12-50-29
PC200, 200LC-6
6735-71-1140 PC200, 200LC-6 HYPER GX 12-50-16
PC200, 200LC-6
6735-71-1141 PC200, 200LC-6 HYPER GX 12-50-17
PC200-6 EXCEL, PC200-6 CUSTOM
6735-71-1150 12-50-18
PC200-6 (BKC), CD60RE-1
6735-71-1160 WA180-3, WA180PT-3
12-50-22
6735-71-1161 WA180-3 (for CIS)
6735-71-1170
WA250PT-3 12-50-25
S6D102E-1 6735-71-1171
6735-71-1181 JV100WA-2, JV100WP-2 12-50-27
6735-71-1210 PC228UU-1 12-50-19
6735-71-1210 PC228USLC-1 12-50-20
6735-71-1260 GD505A-3A 12-50-51
6735-71-1410
PC200-6Z 12-50-52
6735-71-1411
6735-71-1420 WA250-3 12-50-24
6735-71-1420 WA250L-3 (for USA) 12-50-26
6735-71-1440
PC228USLC-2 12-50-21
6735-71-1441
6735-71-1460 GD521A-1E 12-50-28
6735-71-1470 WA180-3 (for EU) 12-50-23
102 SERIES 12-49

(23)
102-2
Engine model Pump assembly No. Engine serial No. Applicable machine Page
6737-71-1110 D39EX-21, D39PX-21 12-50-67
6737-71-1120 D31EX-21, D31PX-21 12-50-68

SAA4D102E-2
6737-71-1130 D37EX-21, D37PX-21 12-50-69
6737-71-1140 WA150-5 12-50-70
6738-71-1110 PC200, LC-7, PC228US, USLC-3 12-50-71
6738-71-1130 BR120T-1 12-50-72
6738-71-1150 WA320-5, WA320PT-5 12-50-73
6738-71-1160 WA250-5, WA250PT-5 12-50-74

SAA6D102E-2
6738-71-1170 WA200-5, WA200PT-5 12-50-76
6738-71-1210 PC220-7, PC220LC-7 12-50-77
6738-71-1310 PC270-7, PC308USLC-3 12-50-75
6738-71-1620 DCA-150ESK (DENYO generator) 12-50-78
102 SERIES 12-49-2

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Injection Pump Assembly Number Applicable Machine Applicable Engine

6731-71-1110 (101402-3801)
Model Serial No. Model Serial No.
( ): Injection Pump Manufacture's part No.
PC60-7, 7B 4D102E-1
Injection Injection Pump
Pump Type Manufactuer PC70-7
BR100JG, RG-1
PES-A ZEXEL
Injection Pump Specification Engine Specification

Rotating direction Clockwise Flywheel horsepower 42.1{56.4}/1,750 (Gross)
(kw{HP)/rpm}
Injection order 1342 Maximum torque (Nm{kgm)/rpm} 249{25.4}/1,200 (Gross)
Injection interval 89 30' 90 30' High idling speed (rpm) 1,900 2,000
Plunger prestroke (mm) 2.45 2.55 Low idling speed (rpm) 1,020 1,070
Delivery valve 3 Pump tester capacity
retraction volume (mm /st) 59
for Service standard Motor: 7.5 kW
Calibration Standard ( ) : Injenction pump manufacture's part number

Conditions Service standard Manufacturer standard
Service standard Nozzle & Nozzle holder part No. (105780 8140) 6732 11 3120
indicates data
using calibration Nozzle part No. (105780 0000)
test parts. Nozzle holder part No. (105780 2080)
Manufacture Injection pipe
standard is data (mm) 6 2 600 6 1.8 600
(Outside dia.x Inside dia.x Length )
for factory Test oil ASTM D975 No.2 diesel fuel or equivalent
test parts.
Oil temperature (C) 40 45
Nozzle opening pressure (MPa{kg/cm2}) 17.2 {175} 21.6 {220}
Transfer pump pressure (kPa{kg/cm2}) 157 {1.6} 157 {1.6}
Injection volume Service standard (cc/1,000 st) Manufacturer standard (cc/1,000 st)
Rack Rack Pump
point position speed Maximum Maximum
variance variance
(mm) (rpm) Injection volume between Injection volume between
Rack positions cylinder cylinder
B to E are the ref-
ernce volume A(Basic point) 10.2 875 77.5 79.5 2.5 59.5
when adjusting the
injection volume. B 10.2 600 71.5 75.5 67.0
Marks are C Approx.7.4 510 # 14 16 15 15
average volumes. D 100 85 95 100
#: Rack position is approx. 8.2 mm

Governor perfomance curve
12-50 102 SERIES

B

6735-71-1160 (101609-3222)
6735-71-1161 (101609-3223) Model Serial No. Model Serial No.
WA180-3 S6D102E-1
Injection Injection Pump WA180PT-3
Pump Type Manufactuer
WA180-3
PES-A ZEXEL (for CIS)

Rotating direction Clockwise Flywheel horsepower 83.4{111.8}/2,400 (Gross)
(kw{HP)/rpm}
Injection order 153624 Maximum torque (Nm{kgm)/rpm} 422{43}/1,600 (Gross)
Plunger prestroke (mm) 2.45 2.55 Low idling speed (rpm) 750 800

Service standard Nozzle & Nozzle holder part No. (105780 8140) 6732 11 3120
indicates data
using calibration Nozzle part No. (105780 0000)
test parts. Nozzle holder part No. (105780 2080)
test parts.
2
Nozzle opening pressure (MPa{kg/cm }) 17.2 {175} 21.6 {220}
2
Transfer pump pressure (kPa{kg/cm }) 157 {1.6} 157 {1.6}
Rack Rack Pump
variance variance
B to E are the ref-
ernce volume A(Basic point) 9.5 1,200 71 73 2.5 64.5
when adjusting the
injection volume. B 9.9 500 54.5 58.5 79
Marks are C 9.7 800 59.5 63.5 70.5
average volumes. D Approx. 8.2 385 8.5 10.5 15 15
E 100 70 80 85
Governor perfomance curve
12-50-22 102 SERIES

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6737-71-1110 (101405-3250)
D39EX-21 SAA4D102E-2
Pump Type Manufactuer D39PX-21
BOSCH automotive
PES-A system

Flywheel horsepower
Rotating direction Clockwise (kw{HP)/rpm} 74{99}/2,200 (Gross)
Injection order 1342 Maximum torque (Nm{kgm)/rpm} 441{45}/1,300 (Gross)

Service standard Nozzle & Nozzle holder part No. (105780 8140) (105158 5010)
indicates data
using calibration Nozzle part No. (105780 0000) (105017 2910)
test parts. Nozzle holder part No. (105780 2080) (105088 2000)
test parts.
Rack Rack Pump
variance variance
B to E are the ref-
ernce volume A(Basic point) 9.8 1,100 102 104 2.5 92.5
when adjusting the
injection volume. B 10.35 650 104 108 116
Marks are C 6.4 420 9 11 15 10
average volumes. E 18 21 100 50 60 70
Governor perfomance curve Boost compensator performance curve
102 SERIES 12-50-67

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6737-71-1120 (101405-3261)
BOSCH automotive
PES-A system

Flywheel horsepower
Rotating direction Clockwise (kw{HP)/rpm} 59.6{79.9}/2,000 (Gross)
Injection order 1342 Maximum torque (Nm{kgm)/rpm} 394.7{40.3}/1,300 (Gross)
Injection interval 89 30' 90 30' High idling speed (rpm) 2,200 50

Plunger prestroke (mm) 2.45 2.55 Low idling speed (rpm) 800 +50
0


indicates data
test parts.
Nozzle opening pressure (MPa{kg/cm2}) 17.2 {175} 22.0 {224.3}
Rack Rack Pump
variance variance
B to E are the ref-
ernce volume A(Basic point) 9.0 1,000 79 1 2.5 81.5 2.5
when adjusting the
injection volume. B 9.75 650 92.5 2 106
Marks are C Apporox 6.4 420 10 1 15 10 15
average volumes. E 18.0 +30 100 70 5 92
12-50-68 102 SERIES

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6737-71-1130 (101405-3271)
BOSCH automotive
PES-A system

Flywheel horsepower
Injection order 1342 Maximum torque (Nm{kgm)/rpm} 420.7{42.9}/1,300 (Gross)

Plunger prestroke (mm) 2.45 2.55 Low idling speed (rpm) 800 +50
0


indicates data
test parts.
Nozzle opening pressure (MPa{kg/cm2}) 17.2 {175} 22.0 {224.3}
Rack Rack Pump
variance variance
B to E are the ref-
ernce volume A(Basic point) 9.7 1,000 93 1 2.5 90 2.5
when adjusting the
injection volume. B 10.35 650 104 2 114.5
Marks are C Apporox 6.4 420 10 1 15 10 15
average volumes. E 18.0 +30 100 70 5 92
102 SERIES 12-50-69

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6737-71-1140 (101405-3340)
WA150-5 SAA4D102E-2
BOSCH automotive
PES-A system

Flywheel horsepower
Injection order 1342 Maximum torque (Nm{kgm)/rpm} 408{41.6}/1,300 (Gross)


indicates data
test parts.
Rack Rack Pump
variance variance
B to E are the ref-
ernce volume A(Basic point) 10.9 1,000 116 1 2.5 102 1 2.5
when adjusting the
injection volume. B (10.9) 650 (116) 2
Marks are C 7.4 415 20 1 15 20 1 15
average volumes. D 18.0 +30 100 (85)
E 9.35 650
12-50-70 102 SERIES

(19)
Fuel Injection Pump Assembly Number Applicable Machine Applicable Engine

6738-71-1150 (101609-3710)
( ): Fuel Injection Pump Manufacture's part No.
WA320-5 SAA6D102E-2
Fuel Injection Fuel Injection Pump WA320PT-5
BOSCH automotive
PES-A system
Fuel Injection Pump Specification Engine Specification

Flywheel horsepower
Rotating direction Clockwise (kw{HP)/rpm} 127{170}/2,000 (Gross)
Fuel Injection order 153624 Maximum torque (Nm{kgm)/rpm} 672{68.5}/1,500 (Gross)
Fuel Injection interval 59 30' 60 30' High idling speed (rpm) 2,200 2,300
Calibration Standard ( ) : Fuel Injenction pump manufacture's part number

indicates data
standard is data (mm)
6 2 600 6 1.8 750
test parts.
2
Rack Rack Pump
variance variance
(mm) (rpm) Fuel Injection volume between Fuel Injection volume between
B to E are the ref-
ernce volume A(Basic point) 11.3 1,000 fl 108.5 1 2.5
when adjusting the
injection volume. B 11.3 750 fl 120
Marks fl are C Approx. 7.5 410 fl 9.5 1 15
average volumes. D 9.5 100 fl 57 5
E 100 fl 130 5
F 11.3 800 (survey)
102 SERIES 12-50-73

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6738-71-1160 (101609-3690)
WA250-5 SAA6D102E-2
Fuel Injection Fuel Injection Pump
Pump Type Manufactuer WA250PT-5
BOSCH automotive
PES-A system

Flywheel horsepower
Fuel Injection order 153624 Maximum torque (Nm{kgm)/rpm} 627{64}/1,400 (Gross)

indicates data
test parts.
Rack Rack Pump
variance variance
B to E are the ref-
ernce volume A(Basic point) 9.7 1,000 100.5 102.5 2.5 93.5
when adjusting the
injection volume. B 10.0 700 105 110
Marks are C 6.5 420 8.5 10.5 15 9.5
average volumes. D 8.8 100 31 41 58
E 100 75 85 105
12-50-74 102 SERIES

(19)

6738-71-1310 (101609-3650)
PC270-7 SAA6D102E-2
Fuel Injection Fuel Injection Pump PC308USLC-3
Pump Type Manufactuer BR380JG-1
BOSCH automotive
PES-A system

Flywheel horsepower
Fuel Injection order 153624 Maximum torque (Nm{kgm)/rpm} 742.4{75.7}/1,500 (Gross)

indicates data
6 2 600 6 1.8 750
test parts.
2
Rack Rack Pump
variance variance
B to E are the ref-
ernce volume A(Basic point) 12.2 1,025 131 133 2.5 116
when adjusting the
injection volume. B 12.2 750 130 127
Marks are C 7.0 525 8.5 10.5 15 9.5
E 100 110 120 130
102 SERIES 12-50-75

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6738-71-1170 (101609-3700)
WA200-5 SAA6D102E-2
Pump Type Manufactuer WA200PT-5
BOSCH automotive
PES-A system

Flywheel horsepower

indicates data
test parts.
Rack Rack Pump
variance variance
B to E are the ref-
ernce volume A(Basic point) 9.1 1,000 81 1 2.5 82
when adjusting the
injection volume. B 9.75 700 95.5 103
Marks are C 6.5 420 9.5 1 15 9.5
E 100 85 5 105
F 9.75 650 93 3 105
12-50-76 102 SERIES

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6738-71-1210 (101609-3640)
PC220-7 SAA6D102E-2
Pump Type Manufactuer PC220LC-7
BOSCH automotive
PES-A system

Flywheel horsepower

indicates data
6 2 600 6 1.8 750
test parts.
2
Rack Rack Pump
variance variance
B to E are the ref-
ernce volume A(Basic point) 12.0 1,000 127.5 129.5 2.5 111.5
when adjusting the
injection volume. B 12.0 750 127.5 124
Marks are C 7.0 525 8.5 10.5 15 9.5
E 100 115 125 145
102 SERIES 12-50-77

(19)

6738-71-1620 (101609-3830)
DCA-150ESK SAA6D102E-2
Fuel Injection Fuel Injection Pump (DENYO generator)
BOSCH automotive
PES-A system

Rotating direction Clockwise Flywheel horsepower 101.4{136.0}/1,500(50Hz)(Gross)
(kw{HP)/rpm} 120.8{162.0}/1,800(60Hz)(Gross)
Fuel Injection order 153624
Max. 1,580 (50Hz)
Fuel Injection interval 60 30' High idling speed (rpm)
Max. 1,890 (60Hz)

indicates data
6 2 600 6 1.8 750
test parts.
Rack Rack Pump
variance variance
B to E are the ref-
ernce volume A(Basic point) 10.8 900 fl 124 1 2.5
when adjusting the B 11.3 900
injection volume. C Approx. 7.6 400 fl 10 1 15
Marks fl are D 10.8 750
average volumes.
E 9.75 100 fl 55 5
F 13.2 100 fl 145 5
G
12-50-78 102 SERIES

(21)
TESTING AND ADJUSTING RUNNING IN STANDARD
The table gives the standard values for machines with fan.
The loads for the dynamometer are at an arm's length of 716 mm.
Engine Applicable Order

Item
model machine 1 2 3 4 5 6
WA120-3D Running time min 2 10 2 3

Engine speed rpm 800850 1,000 1,200 1,600
Load N{kg} 0{0} 98{10} 147{15} 245{25}
Flywheel hosepower kW{HP} 0{0} 7.4{9.9} 13.2{17.7} 29.4{39.4}
D31E,S,Q,P-20 Running time min 2 10 2 3

D31,PL,PLL-20 Engine speed rpm 900950 1,000 1,200 1,600
D31P-20A Load N{kg} 0{0} 98{10} 147{15} 245{25}
S4D102E-1
D37E-5 Running time min 2 10 2 3
D37P-5 Engine speed rpm 800850 1,000 1,200 1,600
Load N{kg} 0{0} 98{10} 147{15} 245{25}
GD305A-3 Running time min 2 10 2 3

Engine speed rpm 650700 1,000 1,200 1,600
Load N{kg} 0{0} 98{10} 147{15} 245{25}
D41A-6 Running time min 3 4 2 2 10 5

Engine speed rpm 700 1,200 1,400 1,400 1,400 2,400
6D102E-1
Load N{kg} 0{0} 88{9.0} 176{18.0} 264{27.0} 343{35.0} 282{29.0}
Flywheel hosepower kW{HP} 0{0} 10.9{14.8} 25.5{34.7} 38.2{52.0} 50.4{68.5} 70.0{95.0}
PC200,200LC-6
Running time min 2 10 2 3
PC200,200LC-6
HYPER GX Engine speed rpm 1,0001,050 1,000 1,200 1,600
BR200S-1 Load N{kg} 0{0} 98{10} 250{25} 440{45}
PC210,210LC-6 Flywheel hosepower kW{HP} 0{0} 7.4{9.9} 22{29.6} 53{71}
MIGHTY
PC228USLC-1 Running time min 2 10 2 3
Engine speed rpm 1,0001,050 1,000 1,200 1,600
Load N{kg} 0{0} 98{10} 250{25} 440{45}
Flywheel hosepower kW{HP} 0{0} 7.4{9.9} 22{29.6} 53{71}
PC228USLC-2 Running time min 2 10 2 3

Engine speed rpm 1,0001,050 1,000 1,200 1,600
S6D102E-1
Load N{kg} 0{0} 98{10} 250{25} 440{45}
D41E, P-6 Running time min 3 4 2 2 10 5

Engine speed rpm 700 1,200 1,300 1,300 1,300 2,400
Load N{kg} 0{0} 115{9.0} 230{23.0} 345{35.0} 461{47.0} 325{33.0}
Flywheel hosepower kW{HP} 0{0} 14.0{19.0} 30.9{42.0} 46.3{63.0} 61.8{84.0} 80.9{110}
WA180-3 Running time min 2 10 2 3

WA180-3 Engine speed rpm 750800 1,000 1,200 1,600
(for CIS) Load N{kg} 0{0} 98{10} 250{25} 440{45}
12-51-1 102 SERIES

(23)
102-2

Item
D31EX-21 Running time min 2 10 2 3 3

D31PX-21 Engine speed rpm 800 1,000 1,200 1,600 2,000
Load N{kg} 0{0} 49{5} 98{10} 206{21} 397{40}
Flywheel hosepower kW{HP} 0{0} 3.7{5} 8.8{11.8} 25{33.5} 60{80.4}

Load N{kg} 0{0} 49{5} 98{10} 206{21} 451{46}
SAA4D
102E-2
Load N{kg} 0{0} 49{5} 98{10} 206{21} 440{45}
WA150-5 Running time min 2 10 2 3 3

Engine speed rpm 825 1,000 1,200 1,600 2,000
Load N{kg} 0{0} 49{5} 98{10} 206{21} 490{50}
102 SERIES 12-51-10

(19)

Item
PC200-7 Running time min 2 10 2 3 3

PC200LC-7 Engine speed rpm 1,050 1,000 1,200 1,600 1,950
PC228US-3 Load N{kg} 0{0} 98{10} 245{25} 440{45} 765{78}
PC228USLC-3 Flywheel hosepower kW{HP} 0{0} 7.4{9.7} 22{29} 53{71} 112{150}

PC308USLC-3 Engine speed rpm 1,050 1,000 1,200 1,600 2,050
BR380JG-1 Load N{kg} 0{0} 98{10} 245{25} 440{45} 911{93}
Flywheel hosepower kW{HP} 0{0} 7.4{9.7} 22{29} 53{71} 140{188}

PC220LC-7 Engine speed rpm 1,050 1,000 1,200 1,600 2,000
Load N{kg} 0{0} 98{10} 245{25} 440{45} 882{90}

WA200PT-5 Engine speed rpm 825 1,000 1,200 1,600 2,000
Load N{kg} 0{0} 98{10} 245{25} 440{45} 628{64}
SAA6D
102E-2
Load N{kg} 0{0} 98{10} 245{25} 440{45} 696{71}

Load N{kg} 0{0} 98{10} 245{25} 440{45} 843{86}
GD555-3A Running time min 2 10 2 3 3

GD555-3C Engine speed rpm 1,050 1,000 1,200 1,600 2,000
Load N{kg} 0{0} 98{10} 245{25} 440{45} 830{85}
DCA-150ESK Running time min 2 10 2 3 3

(DENYO Engine speed rpm 800 1,100 1,300 1,500 1,800
generator) Load N{kg} 0{0} 98{10} 245{25} 440{45} 887{90.5}
Flywheel hosepower kW{HP} 0{0} 7.4{10} 24{33} 50{67} 120{161}
12-51-11 102 SERIES

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TESTING AND ADJUSTING PERFORMANCE TEST CRITERIA
PERFORMANCE TEST CRITERIA

This table gives the standard values using the JIS compensation
factor.
The values in the table are the standard values for machines with
the muffler installed, air cleaner installed, alternator under no
load, and air compressor opened (if installed).
The loads for the dynamometer are at an arm's length of 716
mm.
102-1
Engine Applicable Engine Dynamometer

Test item Specifications Speed
model machine (N{kg})
(rpm)
PC60-7 Flywheel horsepower 40.5 kW/1,750 rpm(Net) 1,745 1,755 312 331
PC70-7 {54.2 HP/1,750 rpm}(Net) {31.8 33.8}
PC60-7B Max. torque 245 Nm/1,200 rpm(Net) 1,100 1,300 348 364
4D102E-1
{25 kgm/1,200 rpm}(Net) {35.5 37.1}
High idling speed 1,900 2,000 rpm 1,900 2,000
Low idling speed 1,020 1,070 rpm 1,020 1,070
PC100L-6 {80.9 HP/2,100 rpm}(Net) {39.6 41.9}
Max. torque 329 Nm/1,300 rpm(Net) 1,200 1,400 466 520
{33.5 kgm/1,300 rpm}(Net) {47.5 53.0}
Low idling speed 900 950 rpm 900 950
EXCEL {80.9 HP/2,100 rpm}(Net) {39.6 41.9}
{33.5 kgm/1,300 rpm}(Net) {47.5 53.0}
PC130-6 {85.8 HP/2,200 rpm}(Net) {40.3 42.5}
MIGHTY Max. torque 329 Nm/1,300 rpm(Net) 1,200 1,400 466 520
S4D102E-1 {33.5 kgm/1,300 rpm}(Net) {47.5 53.0}
EXCEL {83.8 HP/2,000 rpm}(Net) {42.8 45.4}
{33.5 kgm/1,300 rpm}(Net) {47.5 53.1}
PC128UU-1 Flywheel horsepower 62.5 kW/1,900 rpm(Net) 1,895 1,905 434 460
{83.8 HP/1,900 rpm}(Net) {44.3 46.9}
Max. torque 329 Nm/1,300 rpm(Net) 1,200 1,400 Min. 465
{33.5 kgm/1,300 rpm}(Net) {Min. 47.5}
12-52 102 SERIES

(14)
For fuel, use ASTM D975 No. 1 or No. 2.

For lubricant, use SAE15W-40 or SAE30 oil.
Flywheel Fuel Cooling water Lubricating oil Lubricating oil Exhaust

hosepower Torque
consumption temperature temperature pressure temperature
(kW{HP}) (Nm{kgm})
(sec/100cc) (C) (C) (kPa{kg/cm2}) (C)
40.943.4 (Gross) Min. 29.1 75 95 90 110 340 590 Max. 600

{54.858.2}(Gross) {3.5 6.0}
249261 (Gross) 75 95 90 110 Max. 650
{25.426.6}(Gross)
75 95 90 110
75 95 80 110 Min.147 {Min.1.5}
61.164.8 (Gross) Min. 19.4 75 95 90 110 340 590 Max. 600

{83.088.1}(Gross) {3.5 6.0}
333273 (Gross) 75 95 90 110 Max. 650
{34.038.0}(Gross)
75 95 90 110
75 95 80 110 Min.147 {Min.1.5}
61.164.8 (Gross) Min. 19.7 75 95 90 110 340 590 Max. 600

{83.188.1}(Gross) {3.5 6.0}
333373 (Gross) 75 95 90 110 Max. 650
{34.038.0}(Gross)
75 95 90 110
75 95 80 110 Min.147 {Min.1.5}
65.168.9 (Gross) Min. 19.4 75 95 90 110 340 590 Max. 600

{87.292.4}(Gross) {3.5 6.0}
333373 (Gross) 75 95 90 110 Max. 650
{34.038.0}
75 95 90 110
75 95 80 110 Min.147 {Min.1.5}
62.966.7 (Gross) Min. 19.0 75 95 90 110 340 590 Max. 600

{ }(Gross) {3.5 6.0}
333372 (Gross) 75 95 90 110
{34.038.0}(Gross)
75 95 90 110
75 95 80 110 Min.147 {Min.1.5}
61.865.6 (Gross) Min. 19.0 75 95 90 110 340 590 Max. 600

{84.089.2}(Gross) {3.5 6.0}
Min. 330(Gross) 75 95 90 110
{Min. 34}(Gross)
74 95 90 110
75 95 80 110 Min.147 {Min.1.5}
102 SERIES 12-53

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factor.
mm.

(rpm)
D31E,S,Q,P-20 Flywheel horsepower 52.2 kW/2,350 rpm(Net) 2,345 2,355 309 325
D31,PL,PLL-20 {70.0 HP/2,350 rpm}(Net) {31.5 33.2}
D31P-20A Max. torque 265 Nm/1,400 rpm(Net) 1,300 1,500 402 425
{27 kgm/1,400 rpm}(Net) {41.0 43.04}
D37E-5 Flywheel horsepower 56.2 kW/2,500 rpm(Net) 2,495 2,505 305 323
D37P-5A {75.3 HP/2,500 rpm}(Net) {31.1 32.9}
{29.9 kgm/1,400 rpm}(Net) {41.0 43.4}
PC128US-1 Flywheel horsepower 64.0 kW/2,200 rpm(Net) 2,195 2,205 395 417
{85.8 HP/2,200 rpm}(Net) {40.3 42.5}
{33.5 kgm/1,300 rpm}(Net) {47.5 53.0}
S4D102E-1
{85.8 HP/2,200 rpm}(Net) {40.3 42.5}
{33.5 kgm/1,300 rpm}(Net) {47.5 53.0}
{98.7 HP/2,300 rpm}(Net) {44.0 48.4}
{39.5 kgm/1,500 rpm}(Net) {53.5 59.1}
GD305A-3 Flywheel horsepower 63 kW/2,500 rpm(Net) 2,495 2,505 347 367

{85 HP/2,500 rpm}(Net) {35.4 37.4}
{35 kgm/1,500 rpm}(Net) {48.2 50.9}
12-53-1 102 SERIES

(17)


hosepower Torque
(kW{HP}) (Nm{kgm})
54.357.5 (Gross) Min. 20.9 75 95 90 110 390 590 Max. 550

{73.878.2}(Gross) {3.5 6.0}
287305 (Gross) 75 95 90 110 Max. 600
{29.331.1}(Gross)
75 95 90 110
75 95 80 110 Min.147 {Min.1.5}
57.160.6 (Gross) Min. 19.6 75 95 90 110 340 590 Max. 550

{76.581.2}(Gross) {3.5 6.0}
287305 (Gross) 75 95 90 110 Max. 600
{29.331.1}(Gross)
75 95 90 110
75 95 80 110 Min.147 {Min.1.5}
65.168.9 (Gross) 75 95 90 110 340 590 Max. 600

{87.392.4}(Gross) {3.5 6.0}
333373 (Gross) 75 95 90 110 Max. 650
{34.038.0}(Gross)
75 95 90 110
75 95 80 110 Min.147 {Min.1.5}
65.168.9 (Gross) 75 95 90 110 340 590 Max. 600

{87.392.4}(Gross) {3.5 6.0}
333373 (Gross) 75 95 90 110 Max. 650
{34.038.0}(Gross)
75 95 90 110
75 95 80 110 Min.147 {Min.1.5}
74.581.9 (Gross) 75 95 90 110 340 590 Max. 650

{100.0109.8}(Gross) {3.5 6.0}
376415 (Gross) 75 95 90 110 340 590 Max. 650
{38.342.3}(Gross) {3.5 6.0}
75 95 90 110 340 590
{3.5 6.0}
75 95 80 110 Min.147 {Min.1.5}
65.068.8 (Gross) 75 95 90 110 390 590 Max. 600

{87.292.3}(Gross) {3.5 6.0}
338358 (Gross) 75 95 90 110 Max. 650
{34.536.5}(Gross)
75 95 90 110
75 95 80 110 Min.118 {Min.1.2}
102 SERIES 12-53-2

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factor.
mm.

(rpm)
WA120-3 Flywheel horsepower 67.7 kW/2,400 rpm(Net) 2,395 2,405 369 390
{90.7 HP/2,400 rpm}(Net) {37.6 39.8}
{35.5 kgm/1,600 rpm}(Net) {48.8 51.8}
S4D102E-1
WA120-3D Flywheel horsepower 67.7 kW/2,400 rpm(Net) 2,395 2,405 369 390
{90.7 HP/2,400 rpm}(Net) {37.6 39.8}
{35.5 kgm/1,600 rpm}(Net) {48.8 51.8}
D41A-6 Flywheel horsepower 59.7 kW/2,400 rpm(Net) 2,395 2,405

{80.0 HP/2,400 rpm}(Net)
Max. torque 343 Nm/1,300 rpm(Net) 1,200 1,400
6D102E-1
{35.0 kgm/1,300 rpm}(Net)
High idling speed 2,650 rpm 2,600 2,700
Low idling speed 825 rpm 775 875
PC200,200LC-6 Flywheel horsepower 99.3 kW/2,000 rpm(Net) 1,995 2,005 682 721
PC200,200LC-6 {133 HP/2,000 rpm}(Net) {69.5 73.5}
HYPER GX Max. torque 563 Nm/1,350 rpm(Net) 1,250 1,450 782 827
PC210,210LC-6 {57.4 kgm/1,350 rpm}(Net) {79.7 84.3}
MIGHTY High idling speed 2,340 2,460 rpm 2,340 2,460
BR200S-1 Low idling speed 1,000 1,050 rpm 1,000 1,050
PC200LC-6 Flywheel horsepower 95.6 kW/2,000 rpm(Net) 1,995 2,005 658 695
EXCEL {128 HP/2,000 rpm}(Net) {67.1 70.9}
PC200-6 Max. torque 545 Nm/1,350 rpm(Net) 1,250 1,450 756 802
S6D102E-1 CUSTOM {55.6 kgm/1,350 rpm}(Net) {77.1 81.8}
CD60RE-1 High idling speed 2,140 2,260 rpm 2,140 2,260
Low idling speed 975 1,025 rpm 975 1,025
PC228UU-1 Flywheel horsepower 95.6 kW/2,000 rpm(Net) 1,995 2,005 658 695
{128 HP/2,000 rpm}(Net) {67.1 70.9}
{55.6 kgm/1,350 rpm}(Net) {77.1 81.8}
12-53-3 102 SERIES

(17)


hosepower Torque
(kW{HP}) (Nm{kgm})
66.370.4 (Gross) 75 95 90 110 390 590 Max. 650

{90.295.7}(Gross) {3.5 6.0}
322364 (Gross) 75 95 90 110 Max. 650
{34.937.1}(Gross)
75 95 90 110
75 95 80 110 Min.147 {Min.1.5}
66.370.4 (Gross) 75 95 90 110 390 590 Max. 650

{90.295.7}(Gross) {3.5 6.0}
322364 (Gross) 75 95 90 110 Max. 650
{34.937.1}(Gross)
75 95 90 110
75 95 80 110 Min.147 {Min.1.5}
67.374.3 (Gross) 80 85 80 110 580 520 Max. 550

{90.299.6}(Gross) {2.8 5.3}
330366 (Gross) 80 85 80 110
{33.737.3}(Gross)
80 85 80 110
80 85 80 110 Min.70 {Min.0.7}
102108 (Gross) Min. 12.0 75 95 90 110 390 590 Max. 650

{138.9147.1}(Gross) {3.5 6.0}
559592 (Gross) 75 95 90 110 Max. 650
{57.060.4}(Gross)
75 95 90 110
75 95 80 110 Min.147 {Min.1.5}
98.6104 (Gross) Min. 12.5 75 95 90 110 390 590 Max. 650

{132140}(Gross) {3.5 6.0}
541574 (Gross) 75 95 90 110 Max. 650
{55.258.6}(Gross)
75 95 90 110
75 95 80 110 Min.147 {Min.1.5}
98.6104 (Gross) Min. 12.5 75 95 90 110 390 590 Max. 600

{132140}(Gross) {3.5 6.0}
541575 (Gross) 75 95 90 110 Max. 650
{55.258.6}(Gross)
75 95 90 110
75 95 80 110 Min.147 {Min.1.5}
102 SERIES 12-53-4

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factor.
mm.

(rpm)
PC228USLC-1 Flywheel horsepower 95.6 kW/2,000 rpm(Net) 1,955 2,005 658 695
{128 HP/2,000 rpm}(Net) {67.1 70.9}
{55.6 kgm/1,350 rpm}(Net) {77.1 81.8}
PC228USLC-2 Flywheel horsepower 95.6 kW/2,000 rpm(Net) 1,995 2,005 658 695
{128 HP/2,000 rpm}(Net) {67.1 70.9}
{55.6 kgm/1,350 rpm}(Net) {77.1 81.8}
High idling speed 2,140 2,260 rpm
Low idling speed 1,000 1,050 rpm
D41E, P-6 Flywheel horsepower 78.0 kW/2,400 rpm(Net) 2,395 2,405

{105 HP/2,400 rpm}(Net)
Max. torque 461 Nm/1,300 rpm(Net) 1,200 1,400
{47.0 kgm/1,300 rpm}(Net)
High idling speed 2,650 rpm 2,600 2,700
Low idling speed 825 rpm 775 875
S6D102E-1
WA180-3 Flywheel horsepower 81 kW/2,400 rpm(Net) 2,395 2,405 449 478
{108 HP/2,400 rpm}(Net) {45.8 48.7}
WA180-3 Max. torque 417 Nm/1,600 rpm(Net) 1,500 1,700 566 606
(for CIS) {42.5 kgm/1,600 rpm}(Net) {57.7 61.8}

(for EU) {108 HP/2,400 rpm}(Net) {45.8 48.7}
{42.5 kgm/1,600 rpm}(Net) {57.7 61.8}
WA180PT-3 Flywheel horsepower 81 kW/2,400 rpm(Net) 2,395 2,405 449 478

{108 HP/2,400 rpm}(Net) {45.8 48.7}
{42.5 kgm/1,600 rpm}(Net) {57.7 61.8}
Low idling speed 750 800 rpm
12-53-5 102 SERIES

(23)


hosepower Torque
(kW{HP}) (Nm{kgm})
98.6104.4(Gross) 75 95 90 110 340 590 Max. 600

{132140} (Gross) {3.5 6.0}
541575 (Gross) 75 95 90 110 Max. 650
{55.258.6}(Gross)
75 95 90 110
75 95 80 110 Min.147 {Min.1.5}
98.6104.4(Gross) 75 95 90 110 340 590 Max. 600

{132140} (Gross) {3.5 6.0}
541575 (Gross) 75 95 90 110 Max. 650
{55.258.6}(Gross)
75 95 90 110
75 95 80 110 Min.147 {Min.1.5}
79.086.0 (Gross) 80 85 80 110 580 520 Max. 600

{105115} (Gross) {2.8 5.3}
447474 (Gross) 80 85 80 110
{45.648.4}(Gross)
80 85 80 110
80 85 80 110 Min.70 {Min.0.7}
8186 (Gross) 75 95 90 110 340 590 Max. 600

{108115}(Gross) {3.5 6.0}
405434 (Gross) 75 95 90 110 Max. 650
{41.344.3}(Gross)
75 95 90 110
75 95 80 110 Min.147 {Min.1.5}
8186 (Gross) 75 95 90 110 340 590 Max. 600

{108115}(Gross) {3.5 6.0}
405434 (Gross) 75 95 90 110 Max. 650
{41.344.3}(Gross)
75 95 90 110
75 95 80 110 Min.147 {Min.1.5}
8186 (Gross) 75 95 90 110 340 590 Max. 600

{108115}(Gross) {3.5 6.0}
405434 (Gross) 75 95 90 110 Max. 650
{41.344.3}(Gross)
75 95 90 110
75 95 80 110 Min.147 {Min.1.5}
102 SERIES 12-53-6

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factor.
mm.

(rpm)

{123 HP/2,400 rpm}(Net) {52.0 54.8}
{4 kgm/1,600 rpm}(Net) {64.1 68.0}
WA250PT-3 Flywheel horsepower 92 kW/2,400 rpm(Net) 2,395 2,405 510 537

{123 HP/2,400 rpm}(Net) {52.0 54.8}
{4 kgm/1,600 rpm}(Net) {64.1 68.0}
WA250L-3 Flywheel horsepower 92.6 kW/2,400 rpm(Net) 2,395 2,405 535 568
(for USA) {124 HP/2,400 rpm}(Net) {54.6 57.9}
S6D102E-1 {49.3 kgm/1,600 rpm}(Net) {68.4 72.6}
GD521A-1E Flywheel horsepower 104 kW/2,500 rpm(Net) 2,495 2,505 561 593
{140 HP/2,500 rpm}(Net) {57.2 60.5}
{53.5 kgm/1,600 rpm}(Net) {73.4 77.7}
JV100WA-2 Flywheel horsepower 99.3 kW/2,000 rpm(Net) 1,995 2,005 682 721
JV100WP-2 {133 HP/2,000 rpm}(Net) {69.5 73.5}
{57.4 kgm/1,350 rpm}(Net) {79.7 84.3}
12-53-7 102 SERIES

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hosepower Torque
(kW{HP}) (Nm{kgm})
91.796.9 (Gross) 75 95 90 110 340 590 Max. 600

{124.7131.7}(Gross) {3.5 6.0}
450478 (Gross) 75 95 90 110 Max. 650
{45.948.7}(Gross)
75 95 90 110
75 95 80 110 Min.147 {Min.1.5}
91.796.9 (Gross) 75 95 90 110 340 590 Max. 600

{124.7131.7}(Gross) {3.5 6.0}
450478 (Gross) 75 95 90 110 Max. 650
{45.948.7}(Gross)
75 95 90 110
75 95 80 110 Min.147 {Min.1.5}
96102 (Gross) 75 95 90 110 340 590 Max. 600

{129137}(Gross) {3.5 6.0}
481510 (Gross) 75 95 90 110 Max. 650
{49.052.0}(Gross)
75 95 90 110
75 95 80 110 Min.147 {Min.1.5}
105111 (Gross) 75 95 90 110 340 590 Max. 600

{140.8149.3}(Gross) {3.5 6.0}
515546 (Gross) 75 95 90 110 Max. 650
{52.555.7}(Gross)
75 95 90 110
75 95 80 110 Min.147 {Min.1.5}
102108 (Gross) Min. 12.0 75 95 90 110 390 590 Max. 650

{137145}(Gross) {3.5 6.0}
559592 (Gross) 75 95 90 110 Max. 650
{57.060.4}(Gross)
75 95 90 110
75 95 80 110 Min.147 {Min.1.5}
102 SERIES 12-53-8

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factor.
mm.

(rpm)
PC220,LC-6 Flywheel horsepower 118 kW/2,100 rpm(Net) 2,095 2,105 769 814
PC250HD-1 {158 HP/2,100 rpm}(Net) {78.4 83.0}
PC250,LC-6 Max. torque 618 Nm/1,400 rpm(Net) 1,300 1,500 861 914
{63 kgm/1,400 rpm}(Net) {87.8 93.2}
WA300L-3 Flywheel horsepower 114 kW/2,350 rpm(Net) 2,345 2,355 657 694
(for USA) {153 HP/2,350 rpm}(Net) {67.0 70.8}
{62 kgm/1,600 rpm}(Net) {85.5 90.5}
PC220,LC-6 Flywheel horsepower 114 kW/2,100 rpm(Net) 2,095 2,105 745 788
EXCEL {153 HP/2,100 rpm}(Net) {76.0 80.4}
SA6D102E-1 {60 kgm/1,400 rpm}(Net) {83.6 89.1}
Low idling speed 975 1,025 rpm
AVANCE {153 HP/2,350 rpm}(Net) {67.0 70.8}
CUSTOM Max. torque 608 Nm/1,600 rpm(Net) 1,500 1,700 838 888
{62 kgm/1,600 rpm}(Net) {85.5 90.5}
DCA-125SSK Flywheel horsepower 115.5 kW/1,800 rpm(Net) 60Hz 1,795 1,805 861 914
(DENYO 154.8 HP/1,800 rpm(Net) 60Hz {87.8 93.2}
generator) Max. torque
High idling speed Max. 1,890 rpm

12-53-9 102 SERIES

(17)


hosepower Torque
(kW{HP}) (Nm{kgm})
121128 (Gross) Min. 10.7 75 95 90 110 390 590 Max. 600

{162172}(Gross) {3.5 6.0}
616655 (Gross) 75 95 90 110 Max. 650
{62.866.8}(Gross)
75 95 90 110
75 95 80 110 Min.147
116123 (Gross) Min. 10.1 75 95 90 110 390 590 Max. 650

{155164}(Gross) {3.5 6.0}
600635 (Gross) 75 95 90 110 Max. 650
{61.264.8}(Gross)
75 95 90 110
75 95 80 110 Min.147 {Min.1.5}
117.4124.3 (Gross) 75 95 90 110 340 590 Max. 600

{157.4166.6}(Gross) {3.5 6.0}
586626 (Gross) 75 95 90 110 Max. 650
{59.863.8}(Gross)
75 95 90 110
75 95 80 110 Min.147 {Min.1.5}
115.8122.5 (Gross) 75 95 90 110 340 590 Max. 650

{155.2164.3}(Gross) {3.5 6.0}
600635 (Gross) 75 95 90 110 Max. 650
{61.264.8}(Gross)
75 95 90 110
75 95 80 110 Min.147 {Min.1.5}
116.3123.5 (Gross) 70 90 90 110 340 490 Max. 650

{155.9165.6}(Gross) {3.5 5.0}

70 90 90 110
70 90 80 110 Min.147 {Min.1.5}
102 SERIES 12-53-10

(17)
factor.
mm.
102-2

(rpm)
D31EX-21 Flywheel horsepower 55.9 kW/2,000 rpm(Net) 2,000 5 361 384

D31PX-21 {74.9 HP/2,000 rpm}(Net) {36.9 39.2}
Max. torque 384 Nm/1,300 rpm(Net) 1,300 100 520 553
{39.2 kgm/1,300 rpm}(Net) {53.1 56.4}
High idling speed 2,200 50 rpm 2,200 50
Low idling speed 800 +50

0 rpm 800
+50
0
D37EX-21 Flywheel horsepower 63.3 kW/2,000 rpm(Net) 2,000 5 409 434

D37PX-21 {84.9 HP/2,000 rpm}(Net) {41.7 44.3}
{42 kgm/1,300 rpm}(Net) {55.9 61.4}

0 rpm 800
+50
0
D39EX-21 Flywheel horsepower 70 kW/2,200 rpm(Net) 2,200 5 436 462

D39PX-21 {94 HP/2,200 rpm}(Net) {44.5 47.1}
SAA4D
{44.3 kgm/1,300 rpm}(Net) {59.6 66.0}
102E-2 High idling speed 2,400 50 rpm 2,400 50

0 rpm 800
+50
0
PC160LC-7 Flywheel horsepower 82 kW/2,200 rpm(Net) 2,200 5 493 545

{110 HP/2,200 rpm}(Net) {50.3 55.6}
{44 kgm/1,500 rpm}(Net) {58.9 65.3}
Low idling speed 1,050 50 rpm 1,050 50
WA150-5 Flywheel horsepower 74.2 kW/2,000 rpm(Gross) 2,000 5 470 520

{99.5 HP/2,000 rpm}(Gross) {48 53}
Max. torque 408 Nm/1,300 rpm(Gross) 1,300 100 541 598
{41.6 kgm/1,300 rpm}(Gross) {55.2 61}
Flywheel horsepower
Max. torque
High idling speed
Low idling speed
12-53-21 102 SERIES

(19)

Flywheel Torque Fuel Cooling water Lubricating oil Lubricating oil Exhaust
hosepower consumption temperature temperature pressure temperature
(kW{HP}) (Nm{kgm})
57.861.3 (Gross) 75 95 90 110 340 590 Max. 650

{77.582.2}(Gross) {3.5 6.0}
380404 (Gross) 75 95 90 110 340 590 Max. 650
{38.841.2}(Gross) {3.5 6.0}
75 95 90 110 340 590
{3.5 6.0}
75 95 80 110 Min.147{1.5}
65.669.7 (Gross) 75 95 90 110 340 590 Max. 650

{87.993.4}(Gross) {3.5 6.0}
392431 (Gross) 75 95 90 110 340 590 Max. 650
{4044} (Gross) {3.5 6.0}
75 95 90 110 340 590
{3.5 6.0}
75 95 80 110 Min.147{1.5}
72.076.3 (Gross) Min. 16.7 75 95 90 110 340 590 Max. 650

{91.5102.2}(Gross) {3.5 6.0}
419464 (Gross) 75 95 90 110 340 590 Max. 650
{42.747.3}(Gross) {3.5 6.0}
75 95 90 110 340 590
{3.5 6.0}
75 95 80 110 Min.147{1.5}
81.490.0 (Gross) 75 95 90 110 340 590 Max. 650

{109.1120.6}(Gross) {3.5 6.0}
413459 (Gross) 75 95 90 110 340 590 Max. 650
{42.246.8}(Gross) {3.5 6.0}
75 95 90 110 340 590
{3.5 6.0}
75 95 80 110
70.577.9 (Gross) 75 95 90 110 340 590 Max. 650

{94.5104.4}(Gross) {3.5 6.0}
388428 (Gross) 75 95 90 110 340 590 Max. 650
{39.543.7}(Gross) {3.5 6.0}
75 95 90 110 340 590
{3.5 6.0}
75 95 80 110 Min.147{1.5}
102 SERIES 12-53-22

(19)
factor.
mm.

(rpm)
PC200-7 Flywheel horsepower 107 kW/950 rpm(Net) 1,950 50 740 780

PC200LC-7 {143 HP/950 rpm}(Net) {75.6 80.8}
PC228US-3 Max. torque 610 Nm/1,500 rpm(Net) 1,500 100 810 890
PC228 {62.2 kgm/1,500 rpm}(Net) {82.6 90.9}
USLC-3 High idling speed 2,200 30 rpm 2,200 30
BR120T-1 Flywheel horsepower 141 kW/2,050 rpm(Gross) 2,050 5

{189 HP/2,050 rpm}(Gross) { }
Max. torque 740 Nm/1,500 rpm(Gross) 1,500 100
{75.7 kgm/1,500 rpm}(Gross) { }

SAA6D
102E-2 PC270-7 Flywheel horsepower 134 kW/2,050 rpm(Net) 2,050 5 871 962
PC308 {180 HP/2,050 rpm}(Net) {88.9 98.2}
USLC-3 Max. torque 718 Nm/1,500 rpm}(Net) 1,500 100 984 1,088
BR380JG-1 {73.3 kgm/1,500 rpm}(Gross) {100.4 111}
High idling speed 2,330 +70
_ 30 rpm 2,330 +70
_ 30
PC220-7 Flywheel horsepower 125 kW/2,000 rpm(Net) 2,000 5 843 931

PC220LC-7 {168 HP/2,000 rpm}(Net) {86 95}
Max. torque 684 Nm/1,500 rpm}(Net) 1,500 100 940 1,036
{69.8 kgm/1,500 rpm}(Net) {95.9 105.7}
High idling speed 2,260 +80
_ 20 rpm 2,260 +80
_ 20
12-53-23 102 SERIES

(19)


hosepower Torque
(kW{HP}) (Nm{kgm})
108115 (Gross) Min. 75 95 90 110 340 590 Max. 650

{144.9153.8}(Gross) {3.5 6.0}
580640 (Gross) 75 95 90 110 340 590 Max. 650
{59.165.1}(Gross) {3.5 6.0}
75 95 90 110 340 590
{3.5 6.0}
75 95 80 110 Min.147 {1.5}
(Gross) Min. 75 95 90 110 340 590 Max. 650

{ }(Gross) {3.5 6.0}
(Gross) 75 95 90 110 340 590 Max. 650
{ }(Gross) {3.5 6.0}
75 95 90 110 340 590
{3.5 6.0}
75 95 80 110 Min.147 {1.5}
134148 (Gross) 75 95 90 110 340 590 Max. 675

{179.6198.6}(Gross) {3.5 6.0}
705779 (Gross) 75 95 90 110 340 590 Max. 675
{71.979.5}(Gross) {3.5 6.0}
75 95 90 110 340 590
{3.5 6.0}
75 95 80 110 Min.147 {1.5}
126.5139.7 (Gross) 75 95 90 110 340 590 Max. 650

{170187}(Gross) {3.5 6.0}
673742 (Gross) 75 95 90 110 340 590 Max. 650
{68.775.7}(Gross) {3.5 6.0}
75 95 90 110 340 590
{3.5 6.0}
75 95 80 110 Min.147 {1.5}
102 SERIES 12-53-24

(19)
factor.
mm.

(rpm)

WA200PT-5 {127.7 HP/2,000 rpm}(Gross) {61.6 67.9}
{59.8 kgm/1,400 rpm}(Gross) {79.3 87.7}

WA250PT-5 {139.5 HP/2,000 rpm}(Gross) {67.3 74.3}
{64 kgm/1,400 rpm}(Gross) {84.9 93.8}
WA320-5 Flywheel horsepower 127 kW/2,000 rpm(Gross) 2,000 5 806 890

WA320PT-5 {170 HP/2,000 rpm}(Gross) {82.2 90.8}
SAA6D {68.5 kgm/1,500 rpm}(Gross) {90.8 100.5}
102E-2 High idling speed 2,250 50 rpm 2,250 50
GD555-3A Flywheel horsepower 124.5 kW/2,000 rpm(Gross) 2,000 5 787 870

GD555-3C {167 HP/2,000 rpm}(Gross) {80.3 88.7}
Max. torque 743 Nm/1,500 rpm(Gross) 1,500 100 984 1,088
{75.7 kgm/1,500 rpm}(Gross) {100.4 111}
DCA-150ESK Flywheel horsepower 113 kW/1,500 rpm(Net, 50Hz) 1,500 5 995 1,056
(DENYO {151 HP/1,500 rpm}(Net, 50Hz) {101.5 107.8}
generator) Max. torque 135 kW/1,800 rpm(Net, 60Hz) 1,800 5 998 1,060
{180 HP/1,800 rpm}(Net, 60Hz) {101.8 108.2}
High idling speed Max.1,580 rpm(50Hz) Max. 1,580 rpm (50Hz)
Max.1,890 rpm(60Hz) Max. 1,890rpm (60Hz)
Low idling speed 800 50 rpm 800 50 rpm
12-53-25 102 SERIES

(21)


hosepower Torque
(kW{HP}) (Nm{kgm})
90.5100 (Gross) 75 95 90 110 340 590 Max. 650

{119.6132.1}(Gross) {3.5 6.0}
557615 (Gross) 75 95 90 110 340 590 Max. 650
{56.862.8}(Gross) {3.5 6.0}
75 95 90 110 340 590
{3.5 6.0}
75 95 80 110 Min.147 {1.5}
99109 (Gross) 75 95 90 110 340 590 Max. 650

{3.5 6.0}
596659 (Gross) 75 95 90 110 340 590 Max. 650
{60.867.2}(Gross) {3.5 6.0}
75 95 90 110 340 590
{3.5 6.0}
75 95 80 110 Min.147 {1.5}
121133 (Gross) 75 95 90 110 340 590 Max. 675

{162.2178.3}(Gross) {3.5 6.0}
638705 (Gross) 75 95 90 110 340 590 Max. 675
{65.171.9}(Gross) {3.5 6.0}
75 95 90 110 340 590
{3.5 6.0}
75 95 80 110 Min.147 {1.5}
118131 (Gross) 75 95 90 110 340 590 Max. 650

{160.8177.7}(Gross) {3.5 6.0}
705779 (Gross) 75 95 90 110 340 590 Max. 675
{71.979.5}(Gross) {3.5 6.0}
75 95 90 110 340 590
{3.5 6.0}
75 95 80 110 Min.147 {1.5}
112119 (Gross) Min. 13.2 75 95 90 110 340 590 Max. 680

{150160}(Gross) {3.5 6.0}
135143 (Gross) Min. 10.7 75 95 90 110 340 590 Max. 680
{180192}(Gross) {3.5 6.0}
75 95 90 110
75 95 80 110 Min.147 {1.5}
102 SERIES 12-53-26

(21)
TESTING AND ADJUSTING TROUBLESHOOTING DEFECTIVE ACTUATION OF FEED PUMP
TROUBLESHOOTING
DEFECTIVE ACTUATION OF
FEED PUMP (DIAPHRAGM TYPE)
Defective actuation of the feed pump is a cause of
low engine output. The diaphragm type pump can-
not be cleaned or reassembled.
The feed pump is driven mechanically by the cam
shaft lobe. Lever where or damage to the lobe will
reduce the feed pump actuation capacity.
The fuel system must not be actuated if the resis-
tance at the intake side (A) is more than 100 mmHg.
If the diaphragm breaks, the fuel will return through
the housing breather hole (B).
The normal drop in pressure at the filter is a maxi-

mum of 21 kPa{0.2 kg/cm2}.
The filter becomes clogged by the dirt in the fuel,
so the drop in pressure increases. If the feed pump
becomes worn, its filtering capacity will drop, and
the fuel will pass through the dirty filter. This will
cause a drop in the engine output.
Caution: If the filter must be replaced frequently to

allow the engine to display its power to
the full, it means that the feed pump is
worn.
Testing feed pump

The output of the fuel feed pump can be tested by
the following two methods.
Test 1: Measure the output pressure with an in-line

pressure gauge.
Test 2: Measure the flow
TEST 1: TESTING OUTPUT PRESSURE
Start the engine and measure the output of the fuel

feed pump with an in-line pressure gauge.
Min. pressure
21kPa{0.2kg/cm2}
12-54 102 SERIES

0
STANDARD VALUE TABLE FOR TESTING,
TESTING AND ADJUSTING ADJUSTING, AND TROUBLESHOOTING
S6D102E-1
WA180-3
PC228USLC-2 D41E, P-6 WA180PT-3 WA180-3 (for EU)
WA180-3 (for CIS)
Standard Permissible Standard Permissible Standard Permissible Standard Permissible
value value value value value value value value
2,140 2,260 2,140 2,260 2,600 2,700 2,600 2,700 2,600 2,700 2,600 2,700 2,600 2,700 2,600 2,700
1,000 1,050 1,000 1,050 825 900 825 900 750 800 750 800 750 800 750 800
Min. 170 Min. 170 Min. 170 170 Min. 170 Min. 170 Min. 170 Min. 170
Min. 120 Min. 120 Min. 120 120 Min. 120 Min. 120 Min. 120 Min. 120
Max. 2.94 7.47 Max. 6.23 6.23 Max. 2.94 7.47 Max. 2.94 7.47
{Max. 300} {762} {Max. 635} {635} {Max. 300} {762} {Max. 300} {762}

Max. 650 700 Max. 650 600 Max. 650 700 Max. 650 700
Max. 5.5 7.5 Max. 5.5 7.5 Max. 5.5 7.5
Max. 2.0 3.0 Max. 1.5 2.5 Max. 2.0 3.0 Max. 2.0 3.0
Max. 1.0 2.0 Max. 1.0 2.0 Max. 1.0 2.0
0.25 0.25 0.25 0.25

0.51 0.51 0.51 0.51
Min. 2.41 1.69 Min. 2.41 2.10 Min. 2.41 1.69 Min. 2.41 1.69
{Min. 24.6} {17.2} {Min. 24.6} {21.1} {Min. 24.6} {17.2} {Min. 24.6} {17.2}
Max. 0.49 0.98 Max. 0.25 0.50 Max. 0.49 0.98 Max. 0.49 0.98
{Max. 50} {100} {Max. 26} {51} {Max. 50} {100} {Max. 50} {100}
340 590 245 280 520 210 340 590 245 340 590 245
{3.5 6.0} {2.5} {2.8 5.3} {2.1} {3.5 6.0} {2.5} {3.5 6.0} {2.5}
290 540 206 290 540 206 290 540 206
{3.0 5.5} {2.1} {3.0 5.5} {2.1} {3.0 5.5} {2.1}
Min. 147 78 Min. 100 70 Min. 147 78 Min. 147 78

{Min. 1.5} {0.80} {Min. 1.0} {0.7} {Min. 1.5} {0.80} {Min. 1.5} {0.80}
Min. 98 69 Min. 98 69 Min. 98 69
{Min. 1.0} {0.70} {Min. 1.0} {0.70} {Min. 1.0} {0.70}
90 110 120 80 110 120 90 110 120 90 110 120
Max. 0.5 1.0 Max. 0.5 1.0 Max. 0.5 1.0 Max. 0.5 1.0
21.6 22.4 18.0 24.0 25.0 21.0 21.6 22.4 18.0 21.6 22.4 18.0
{220 228} {184} {245 255} {215} {220 228} {184} {220 228} {184}
16 18 16 18 14 17 19 17 19 17 19 17 19
0.10 0.10
{1.0} {1.0}
1,690 1,790 1,690 1,790 2,300 2,300 1,630 1,730 1,630 1,730
9.5 12.7 11 15 9.5 12.7 9.5 12.7 9.5 12.7 11 15 9.5 12.7 11 15
102 SERIES 12-209

(23)
102-2
Engine model SAA4D102E-2
Applicable machine model D31EX-21, D31PX-21 D37EX-21, D37PX-21
Cat- Measurement Standard Permissible Standard Permissible

egory item conditions Unit value value value value
High idling speed rpm 2,200 50 2,200 50 2,200 50 2,200 50

Performance
Engine speed
Low idling speed rpm 800 +50
0 800 +50
0 800 +50
0 800 +50
0
Nessary stating 0C (without starting aid) rpm Min. 170 Min. 170 Min. 170 Min. 170
speed -20 (with starting aid) rpm Min. 120 Min. 120 Min. 120 Min. 120
kPa Max. 3.72 7.47 Max. 3.72 7.47

Intake resistance At all speed {mmH2O} {Max. 380} {762} {Max. 380} {762}
Boost pressure At rated flywheel horsepower kPa Min. 93 81 Min. 106 100
{mmHg} {Min. 700} {650} {Min. 800} {750}
Exhaust pressure
At rated flywheel horsepower kPa Min. 120 106 Min. 120 106
Intake, exhaust system
(turbine inlet pressure) {mmHg} {Min. 900} {800} {Min. 900} {800}
Exhaust temperature All speed (20C)
(turbine inlet temp.) C Max. 650 700 Max. 650 700
Quick acceleration
(low idle high idle) Max. 4.5 6.0 Max. 4.0 6.0
Bosch
Exhaust gas color At rated flywheel horsepower index Max. 2.0 3.0 Max. 2.0 3.0
High idling speed Max. 1.0 2.0 Max. 1.0 2.0
Valve clearance Intake valve mm 0.25 0.25

(When engine is hot
or cold) Exhaust valve mm 0.51 0.51
Engine proper
Oil temperature: 40 60C MPa Min. 2.41 1.69 Min. 2.41 1.69
Compression pressure {kg/cm2} {Min. 24.6} {17.2} {Min. 24.6} {17.2}
(SAE30 or SAE15W-40)
(engine speed) (rpm)
Blow-by pressure At rated flywheel horsepower kPa Max. 0.49 0.98 Max. 0.49 0.98
(SAE30 or SAE15W-40) (water temp. : Min. 70C) {mmH2O} {Max. 50} {100} {Max. 50} {100}
At rated flywheel horsepower kPa

SAE 30 or SAE15 W40 oil 340 590 245 340 590 245
{kg/cm2} {3.5 6.0} {2.5} {3.5 6.0} {2.5}
kPa 290 540 206 290 540 206
Oil pressure SAE10W oil
Lubrication system
{kg/cm2} {3.0 5.5} {2.1} {3.0 5.5} {2.1}

(oil temperature :
At low idling kPa
Min. 80C) SAE 30 or SAE15 W40 oil Min. 147 78 Min. 147 78
{kg/cm2} {Min. 1.5} {0.80} {Min. 1.5} {0.80}
kPa Min. 98 69 Min. 98 69
SAE 10W oil {kg/cm2} {Min. 1.0} {0.70} {Min. 1.0} {0.70}
All speed
Oil temperature (Oil in oil pan) C 90 110 120 90 110 120
At continuous rated horsepower

Oil consumption ratio (Ratio for fuel consumption) % Max. 0.2 0.6 Max. 0.2 0.6
+1.4 +1.4
MPa 22 0 18.0 22 0 18.0
system
Fuel injection pressure Nozzle tester {kg/cm2} +15 +15

Fuel
{224 0 } {184} {224 0 } {184}
Fuel injection timing B. T. D. C degree

Opening pressure kPa
Cooling system
Radiator pressure valve (Differential pressure) {kg/cm2}
Fan speed At rated engine speed rpm 1,660 50 1,660 50 1,660 50 1,660 50
Deflection when pushed

Fan belt tension with a force of 60N {6 kg} mm (Auto-tension) (Auto-tension)
12-220 102 SERIES

(19)
SAA4D102E-2
WA150-5

2,250 50 2,250 50
825 50 825 50
Min. 170 Min. 170

Min. 120 Min. 120
Max. 3.72 7.47

{Max. 380} {762}
Min. 106 93
{Min. 800} {700}
Min. 120 106
{Min. 900} {800}
Max. 650 700
Max. 4.0 6.0
Max. 1.5 2.5
Max. 0.5 1.5
0.25
0.51
Min. 2.41 1.69

{Min. 24.6} {17.2}
Max. 0.49 0.98

{Max. 50} {100}
340 590 245

{3.5 6.0} {2.5}
290 540 210
{3.0 5.5} {2.1}
Min. 147 78
{Min. 1.5} {0.80}
Min. 98 69
{Min. 1.0} {0.70}
90 110 120
Max. 0.2 0.6
+1.4
22 0 18.0
+15
{224 0 } {184}
11 1
(Auto-tensioner)
102 SERIES 12-221

(19)
102-2
Applicable machine model D39EX-21, D39PX-21

egory item conditions Unit value value value value
High idling speed rpm 2,400 50 2,400 50

Performance
Engine speed
Low idling speed rpm 800 +50
0 800 +50
0
Nessary stating 0C (without starting aid) rpm Min. 170 Min. 170
speed -20 (with starting aid) rpm Min. 120 Min. 120
kPa Max. 3.72 7.47

Intake resistance At all speed {mmH2O} {Max. 380} {762}
Boost pressure At rated flywheel horsepower kPa Min. 133 127
{mmHg} {Min. 1,000} {950}
Exhaust pressure
At rated flywheel horsepower kPa Min. 153 147
(turbine inlet pressure) {mmHg} {Min. 1,150} {1,100}

Exhaust temperature All speed (20C)
(turbine inlet temp.) C Max. 650 700
Quick acceleration
(low idle high idle) Max. 4.0 6.0
Bosch
Exhaust gas color At rated flywheel horsepower index Max. 2.0 3.0
High idling speed Max. 1.0 2.0
Valve clearance Intake valve mm 0.25

(When engine is hot
or cold) Exhaust valve mm 0.51
Engine proper
Oil temperature: 40 60C MPa Min. 2.41 1.69

Compression pressure {kg/cm2} {Min. 24.6} {17.2}
Blow-by pressure At rated flywheel horsepower kPa Max. 0.49 0.98

(SAE30 or SAE15W-40) (water temp. : Min. 70C) {mmH2O} {Max. 50} {100}

SAE 30 or SAE15 W40 oil 340 590 245
{kg/cm2} {3.5 6.0} {2.5}
kPa 290 540 206
Lubrication system
{kg/cm2} {3.0 5.5} {2.1}

(oil temperature :
At low idling kPa
Min. 80C) SAE 30 or SAE15 W40 oil Min. 147 78
{kg/cm2} {Min. 1.5} {0.80}
kPa Min. 98 69
SAE 10W oil {kg/cm2} {Min. 1.0} {0.70}
All speed
Oil temperature (Oil in oil pan) C 90 110 120

Oil consumption ratio (Ratio for fuel consumption) % Max. 0.2 0.6
+1.4
MPa 22 0 18.0
system
Fuel injection pressure Nozzle tester {kg/cm2} +15

Fuel
{224 0 } {184}
Fuel injection timing B. T. D. C degree 13 1

Cooling system
Fan speed At rated engine speed rpm 1,825 55

Fan belt tension with a force of 60N {6 kg} mm (Auto-tension)
12-221-1 102 SERIES

(19)
PC160LC-7 PC200-7, PC200LC-7 PC228US-3, PC228USLC-3 PC270-7, PC308USLC-3,

BR380JG-1
+70 +70
2,490 50 2,490 50 2,200 30 2,200 30 2,200 30 2,200 30 2,330 _ 30 2,330 _ 30
1,050 50 1,050 50 1,050 25 1,050 25 1,050 25 1,050 25 1,050 25 1,050 25
Min. 170 Min. 170 Min. 170 Min. 170 Min. 170 Min. 170 Min. 170 Min. 170
Max. 3.72 7.47 Max. 3.72 7.47 Max. 3.72 7.47 Max. 3.72 7.47
{Max. 380} {762} {Max. 380} {762} {Max. 380} {762} {Max. 380} {762}
Min. 120 113 Min. 126 113 Min. 126 113 Min. 146 133
{Min. 900} {850} {Min. 950} {850} {Min. 950} {850} {Min. 1,100} {1,000}
Min. 133 127 Min. 120 106 Min. 120 106 Min. 133 120
{Min. 1,000} {950} {Min. 900} {800} {Min. 900} {800} {Min. 1,000} {900}
Max. 650 700 Max. 650 700 Max. 650 700 Max. 675 700
Max. 4.5 6.5 Max. 5.5 7.5 Max. 5.5 7.5 Max. 5.5 7.5
Max. 1.5 2.5 Max. 21.5 2.5 Max. 21.5 2.5 Max. 1.5 2.5
Max. 1.0 2.0 Max. 0.5 1.5 Max. 0.5 1.5 Max. 0.5 1.5
0.25 0.25 0.25 0.25

0.51 0.51 0.51 0.51
Min. 2.41 1.69 Min. 2.41 1.69 Min. 2.41 1.69 Min. 2.41 1.69
{Min. 24.6} {17.2} {Min. 24.6} {17.2} {Min. 24.6} {17.2} {Min. 24.6} {17.2}
Max. 0.49 0.98 Max. 1.2 5.1 Max. 0.49 0.98 Max. 0.49 0.98
{Max. 50} {100} {Max. 123} {520} {Max. 50} {100} {Max. 50} {100}
340 590 245 340 590 245 340 590 245 340 590 245
{3.5 6.0} {2.5} {3.5 6.0} {2.5} {3.5 6.0} {2.5} {3.5 6.0} {2.5}
290 540 206 290 540 210 290 540 210 290 540 210
{3.0 5.5} {2.1} {3.0 5.5} {2.1} {3.0 5.5} {2.1} {3.0 5.5} {2.1}
Min. 147 78 Min. 150 80 Min. 150 80 Min. 150 80

{Min. 1.5} {0.80} {Min. 1.5} {0.80} {Min. 1.5} {0.80} {Min. 1.5} {0.80}
Min. 98 69 Min. 100 70 Min. 100 70 Min. 100 70
{Min. 1.0} {0.70} {Min. 1.0} {0.70} {Min. 1.0} {0.70} {Min. 1.0} {0.70}
90 110 120 90 110 120 90 110 120 90 110 120
Max. 0.2 0.6 Max. 0.2 0.6 Max. 0.2 0.6 Max. 0.2 0.6
+1.4 +1.4 +1.4 +1.4

22 0 18.0 22 0 18.0 22 0 18.0 22 0 18.0
+15 +15 +15 +15
{224 0 } {184} {224 0 } {184} {224 0 } {184} {224 0 } {184}
11 1 11 1 11 1 11.5 1
2,024 60 2,024 60 1,690 50 1,690 50 1,690 50 1,690 50 2,110 50 2,110 50
(Auto-tensioner) (Auto-tensioner) (Auto-tensioner) (Auto-tensioner)
102 SERIES 12-221-2

(22)
WA200-5, WA250-5,
Applicable machine model WA200PT-5 WA250PT-5
egory item conditions Unit value value value vaalue
High idling speed rpm 2,250 50 2,250 50 2,250 50 2,250 50

Performance
Engine speed
Low idling speed rpm 825 50 825 50 825 50 825 50
Nessary stating 0C (without starting aid) rpm Min. 170 Min. 170 Min. 170 Min. 170
speed -20 (with starting aid) rpm Min. 120 Min. 120 Min. 120 Min. 120
kPa Max. 3.72 7.47 Max. 3.72 7.47

Intake resistance At all speed {mmH2O} {Max. 380} {762} {Max. 380} {762}
Boost pressure At rated flywheel horsepower kPa Min. 93 80 Min. 120 106
{mmHg} {Min. 700} {600} {Min. 900} {800}
Exhaust pressure kPa Min. 93 80 Min. 120 106
At rated flywheel horsepower
(turbine inlet pressure) {mmHg} {Min. 700} {600} {Min. 900} {800}
Exhaust temperature
(turbine inlet temp.) All speed (20C) C Max. 650 700 Max. 650 700
Quick acceleration
(low idle high idle) Max. 5.5 7.5 Max. 5.5 7.5
Bosch
Exhaust gas color At rated flywheel horsepower index Max. 2.0 3.0 Max. 1.5 3.0
High idling speed Max. 0.5 1.5 Max. 0.5 1.5
Valve clearance Intake valve mm 0.25 0.25

(When engine is hot
or cold) Exhaust valve mm 0.51 0.51
Engine proper
Oil temperature: 40 60C MPa Min. 2.41 1.69 Min. 2.41 1.69
Compression pressure {kg/cm2} {Min. 24.6} {17.2} {Min. 24.6} {17.2}
Blow-by pressure At rated flywheel horsepower kPa Max. 0.49 0.98 Max. 0.49 0.98
(SAE30 or SAE15W-40) (water temp. : Min. 70C) {mmH2O} {Max. 50} {100} {Max. 50} {100}
At rated flywheel horsepower

SAE 30 or SAE15 W40 oil kPa 340 590 245 340 590 245
{kg/cm2} {3.5 6.0} {2.5} {3.5 6.0} {2.5}
kPa 290 540 210 290 540 210
Lubrication system
{kg/cm2} {3.0 5.5} {2.1} {3.0 5.5} {2.1}

(oil temperature :
At low idling
Min. 80C) SAE 30 or SAE15 W40 oil kPa Min. 150 80 Min. 150 80
{kg/cm2} {Min. 1.5} {0.80} {Min. 1.5} {0.80}
kPa Min. 100 70 Min. 70 70
SAE 10W oil {kg`/cm2} {Min. 1.0} {0.70} {Min. 0.70} {0.70}
All speed
Oil temperature (Oil in oil pan) C 90 110 120 90 110 120

Oil consumption ratio (Ratio for fuel consumption) % Max. 0.2 0.6 Max. 0.2 0.6
+1.4 +1.4
MPa 22 0 18.0 22 0 18.0
system
Fuel injection pressure Nozzle tester {kg/cm2} +15 +15

Fuel
{224 0 } {184} {224 0 } {184}
Fuel injection timing B. T. D. C degree 11 1 10 1

Cooling system
Fan speed At rated engine speed rpm

Fan belt tension with a force of 60N {6 kg} mm (Auto-tension) (Auto-tension)
12-222 102 SERIES

(21)
SAA6D102E-2
WA320-5, GD555-3A, PC220-7,

WA320PT-5 BR120T-1 PC220LC-7
GD555-3C
+80 +80
2,250 50 2,250 50 2,330 50 2,330 50 2,230 50 2,230 50 2,260 _ 20 2,260 _ 20
900 25 900 25 1,050 25 1,050 25 850 50 850 50 1,050 25 850 50
Max. 3.72 7.47 Max. 3.72 7.47 Max. 3.72 7.47 Max. 3.72 7.47
{Max. 380} {762} {Max. 380} {762} {Max. 380} {762} {Max. 380} {762}
Min. 120 106 Min. 146 133 Min. 146 133 Min. 140 133
{Min. 900} {800} {Min. 1,100} {1,000} {Min. 1,100} {1,000} {Min. 1,050} {1,000}
Min. 126 113 Min. 133 120 Min. 140 127 Min. 133 120
{Min. 950} {850} {Min. 1,000} {900} {Min. 1,050} {950} {Min. 1,000} {900}
Max. 675 700 Max. 650 700 Max. 675 700 Max. 650 700
Max. 4.5 6.5 Max. 5.5 7.5 Max. 4.5 5.5 Max. 5.5 7.5
Max. 2.0 3.0 Max. 1.5 2.5 Max. 1.5 2.5 Max. 1.5 2.5
Max. 0.5 1.5 Max. 0.5 1.5 Max. 1.0 2.0 Max. 0.5 1.5
0.25 0.25 0.25 0.25

0.51 0.51 0.51 0.51
Min. 2.41 1.69 Min. 2.41 1.69 Min. 2.41 1.69 Min. 2.41 1.69
{Min. 24.6} {17.2} {Min. 24.6} {17.2} {Min. 24.6} {17.2} {Min. 24.6} {17.2}
Max. 0.49 0.98 Max. 0.49 0.98 Max. 0.49 0.98 Max. 0.49 0.98
{Max. 50} {100} {Max. 50} {100} {Max. 50} {100} {Max. 50} {100}
340 590 245 340 590 245 340 590 245 340 590 245
{3.5 6.0} {2.5} {3.5 6.0} {2.5} {3.5 6.0} {2.5} {3.5 6.0} {2.5}
290 540 210 290 540 210 290 540 210 290 540 210
{3.0 5.5} {2.1} {3.0 5.5} {2.1} {3.0 5.5} {2.1} {3.0 5.5} {2.1}
Min. 150 80 Min. 150 80 Min. 150 80 Min. 150 80

{Min. 1.5} {0.80} {Min. 1.5} {0.80} {Min. 1.5} {0.80} {Min. 1.5} {0.80}
Min. 100 70 Min. 100 70 Min. 100 70 Min. 100 70
{Min. 1.0} {0.70} {Min. 1.0} {0.70} {Min. 1.0} {0.70} {Min. 1.0} {0.70}
90 110 120 90 110 120 90 110 120 90 110 120
Max. 0.2 0.6 Max. 0.2 0.6 Max. 0.2 0.6 Max. 0.2 0.6
+1.4 +1.4
22 0 18.0 22 +1.4
0 18.0 22 0 18.0 22 +1.4
0 18.0
+15 +15
{224 0 } {184} {224 +15
0 } {184} {224 0 } {184} {224 +15
0 } {184}
11 1 13 1 10 0.5 11 1
2,060 50 2,060 50
(Auto-tension) (Auto-tension) (Auto-tension) (Auto-tension)
102 SERIES 12-223

(20)
DCA-150ESK
Applicable machine model (DENYO generator)
Cat- Measurement Standard Permissible
egory item conditions Unit value value
High idling speed rpm Max. 1,580 Max. 1,580

Performance
Engine speed Max. 1,890 Max. 1,890

Low idling speed rpm 800 50 800 50
Nessary stating 0C (without starting aid) rpm Min. 170 Min. 170
speed -20 (with starting aid) rpm Min. 120 Min. 120
kPa Max. 3.72 7.47

Intake resistance At all speed {mmH2O} {Max. 380} {762}
Boost pressure At rated flywheel horsepower kPa
{mmHg}
Exhaust pressure
(turbine inlet pressure)

{mmHg}
Exhaust temperature
(turbine inlet temp.) All speed (20C) C Max. 680 700
Quick acceleration
(low idle high idle)
Bosch
Exhaust gas color At rated flywheel horsepower index Max. 1.5 2.5
High idling speed Max. 0.5 1.5
Valve clearance Intake valve mm 0.25

(When engine is hot mm
or cold) Exhaust valve 0.51
MPa Min. 2.41 1.69

Engine proper
Compression pressure Oil temperature: 40 60C {kg/cm2} {Min. 24.6} {17.2}

(SAE30 or SAE15W-40) (rpm)
(engine speed)
Blow-by pressure At rated flywheel horsepower kPa Max. 0.49 0.98

(SAE30 or SAE15W-40) (water temp. : Min. 70C) {mmH2O} {Max. 50} {100}
At rated flywheel horsepower kPa 340 590 245

SAE 30 or SAE15 W40 oil {kg/cm2} {3.5 6.0} {2.5}
kPa 290 540 210
Oil pressure SAE10W oil {kg/cm2}
Lubrication system
{3.0 5.5} {2.1}

(oil temperature : At low idling kPa Min. 150 80
Min. 80C) SAE 30 or SAE15 W40 oil {kg/cm2} {Min. 1.5} {0.80}
kPa Min. 100 70
SAE 10W oil {kg`/cm2} {Min. 1.0} {0.70}
All speed C
Oil temperature (Oil in oil pan) 90 110 120
At continuous rated horsepower %

Oil consumption ratio (Ratio for fuel consumption) Max. 0.5 1.0
+1.4
MPa 22 18.0
system
0
Fuel injection pressure Nozzle tester {kg/cm2} +15
Fuel
{224 0 } {184}
Fuel injection timing B. T. D. C degree 10.0 1

Cooling system

1,440 40 (50Hz) 1,440 40 (50Hz)
Fan speed At rated engine speed rpm 1,730 50 (60Hz) 1,730 50 (60Hz)
Fan belt tension with a force of 60N {6 kg} mm (Auto-tension)
12-223-1 102 SERIES

(21)
TROUBLESHOOTING S-1
S-1 Starting performance is poor

(Starting always takes time)
General causes why exhaust smoke comes out but
engine takes time to start
Defective electrical system
Causes
Insufficient supply of fuel
Insufficient intake of air
Improper selection of fuel
(At ambient temperature of -10C or below,
ASTM D975 No. 2 diesel fuel is used)
t
elem alve sea
Battery charging rate
lter
Ambient Charging rate
100 % 90 % 80 % 75 % 70 %
ve, v
ze fi
ent
temperature
r
r
r
e
inde
eate
20C 1.28 1.26 1.24 1.23 1.22
rain
gau
f val
0C 1.29 1.27 1.25 1.24 1.23
, cyl
air h
r, st
ump
10C 1.30 1.28 1.26 1.25 1.24
ner
act o
filte
ring
clea
ake
The specific gravity should exceed the value for the
p
cont
feed
fuel
l int
ston
charging rate of 70% in the above table.
a i r
ctive
trica
ged
ged
ged
In cold areas the specific gravity must exceed the
n pi
Defe
Clog
value for the charging rate of 75% in the above table.
Clog
Clog
Elec
Wor
Confirm recent repair history
Degree of use of machine Operated for long period
Gradually became worse
Ease of starting
Starts when warm
Questions
Indicator lamp does not light up

Engine oil must be added more frequently
Replacement of filters has not been carried out according to operation Manual
Non-specified fuel has being used
Dust indicator lamp is red
Battery charge lamp is ON
Starting motor cranks engine slowly
When exhaust manifold is touched immediately after starting engine,
temperature of some cylinders is low
Engine does not pick up smoothly, and combustion is irregular
Blow-by gas is excessive
Check items
Timing lock on fuel injection pump does not match

Mud is stuck to fuel tank cap
When engine is cranked with starting motor,
1) Little fuel comes out even when injection pump piping sleeve nut is loosened
2) Little fuel comes out even when fuel filter air bleed plug is loosened
Leakage from fuel piping
There is hunting from engine (rotation is irregular)
When compression pressure is measured, it is found to be low

When air cleaner element is inspected directly, it is found to be clogged
When fuel filter, strainer are inspected directly, they are found to be clogged
Troubleshooting
When feed pump strainer is inspected directly, it is found to be clogged

Heater mount does not become warm
Is voltage 2630V between alternator terminal B and terminal E Yes
with engine at low idling? No
Either specific gravity of electrolyte or voltage of battery is low
Speed does not change when operation of certain cylinders is stopped
When control rack is pushed, it is found to be heavy or does not return
(check after removing fuel injection pump)
When fuel tank cap is inspected directly, it is found to be clogged
Replace
Replace
Correct
Clean
Clean
Clean
Remedy
Use a test stand

12-256 102 SERIES
(17)
Replace Defe
ctive
Replace Defe regu
lato
ctive r
Replace Defe a ltern
ctive ator
102 SERIES
Replace Defe or d
eter
ctive iora
Adjust Defe injec ted
tion batt
tive nozz ery
Replace Defe
injec
tion le
tive timi
Correct Leak injec ng
tion
age, p ump
Clean
TROUBLESHOOTING
Clog clog (rac

ged ging k, pl
a , air
Replace Defe i r brea i n fuel
ung
er st
ctive ther pipi uck)
Replace f e ed p h o l e in
ng
Defe
Causes
ctive ump fuel

boo tank
st co
mpe
nsat
or c
ance
l
(17)
S-1
12-257
TROUBLESHOOTING S-7
S-7 Exhaust smoke is black

(Incomplete combustion)
General causes why exhaust smoke is black Causes
Insufficient intake of air
Improper condition of fuel injection
d)
d
n)
hea
eize
ctio
Excessive injection of fuel
and
er s
at
pray
inje
e se
lung
rger
ve s
sive
valv
e
ck, p
cha
renc
n tim defecti
xces
and
urbo
p (ra
ent
erfe
(e
r
alve
ing
fler
e
nde
p
lem
zle,
en t
ranc
, int
pum
f
u
of v
noz
u
i
er e
, cyl
twe
on p
ed m
rger
clea
ion
lean
tion
tact
o
e
ring
i
cha
air b
ecti
ject
ject
e
logg
v
con
njec
air c
l
urbo
r inj
a
ston
e in
e in
v
e of
d, c
e
i
r
rope
rope
ged
ctiv
ctiv
ged
ctiv
n pi
ed t
she
kag
Defe
Defe
Defe
Clog
Clog
Wor
Seiz
Imp
Imp
Cru
Lea
Suddenly became black
Color of exhaust gas Gradually became black
Questions
Blue under light load

Suddenly
Power was lost
Gradually
Non-specified fuel is being used
Noise of interference is heard from around turbocharger
Dust indicator lamp is red
Blow-by gas is excessive
Engine pickup is poor and combustion is irregular
When exhaust manifold is touched immediately after
starting engine, temperature of some cylinders is low
Check items
Timing lock on fuel injection pump does not match

Seal on injection pump has come off
Clanging sound is heard from around cylinder head
Exhaust noise is abnormal
Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
When turbocharger is rotated by hand, it is found to be heavy

When air cleaner element is inspected directly, it is found to be
clogged
Troubleshooting
Speed does not change when operation of certain cylinders

is stopped
When check is made using delivery method, injection timing
is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust color returns to normal
When control rack is pushed, it is found to be heavy, or
does not return
Replace
Replace
Replace
Replace
Replace
Replace
Remedy
Correct
Adjust
Adjust
Adjust
Clean
102 SERIES 12-265

(19)
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive

(or exhaust smoke is blue)
Do not run the engine at idling for more than 20 Causes
minutes continuously. (Both low and high idling)
r
arge
e)
General causes why oil consumption is excessive
och
ngin
Turb
ss e
al
d
Abnormal combustion of oil
hea
n se
ace
m
ose
oler
er le
External leakage of oil
surf
yste
der
oke
h
i l co
r (lin
Wear of lubrication system
cylin
her
), br
ke s
seal
plug
o
reat
inde
d
nd
uide
r
inta
n or
ter o
ping
eal,
n
ain
e
er e
or b
, cyl
bine
m, g
om
ar s
il pa
il dr
il pi
il fil
ing
low
ther
r
ring
in fr
n re
oole
t tur
(ste
mo
mo
mo
mo
on r
at b
brea
roke
ston
cked
al a
oil c
e fro
e fro
e fro
e fro
lve
pist
al
n va
n se
n se
ged
n, b
n pi
t su
kag
ken
kag
kag
kag
ken
Clog
Wor
Wor
Wor
Wor
Wor
Dus
Lea
Bro
Lea
Lea
Lea
Bro
Oil consumption suddenly increased
Questions
Engine oil becomes contaminated quickly

Exhaust smoke is blue under light load
Excessive
Amount of blow-by gas
None
Area around engine is dirty with oil
There is oil in engine cooling water
Check items
When exhaust pipe is removed, inside is found to be dirty with oil

When turbocharger air supply pipe is removed, inside is
found to be dirty with oil
Oil level in clutch or TORQFLOW transmission damper
chamber rises
Clamps for intake system are loose

When breather element is inspected, it is found to be
Troubleshooting
clogged with dirty oil

There is external leakage of oil from engine
Pressure-tightness test of oil cooler shows there is leakage
Excessive play of turbocharger shaft
Inspect rear seal directly
When intake manifold is removed, dust is found inside
When intake manifold is removed, inside is found to be
dirty with oil
Replace
Replace
Replace
Replace
Replace
Correct
Correct
Correct
Correct
Correct
Correct
Correct
Clean
Remedy
12-266 102 SERIES

0
13 DISASSEMBLY AND ASSEMBLY
Special tool list ............................................... 13- 6 Removal of fuel injection pump

Special tools for disassembly (Bosch A, Zexle A) .................................. 13-27
and assembly ........................................... 13- 6 Removal of feed pump
Special tools for engine ............................. 13- 8 (engine mount type) .............................. 13-30
Special tools for fuel system ..................... 13-10 Removal of tappet cover ......................... 13-30
Outline of disassembly and assembly Removal of oil filler .................................. 13-30
of engine ....................................................... 13-12 Removal of coolant heater
Outline ........................................................ 13-12 (If applicable) .......................................... 13-30
Disassembly ............................................... 13-12 Removal of oil cooler ............................... 13-31
Assembly .................................................... 13-12 Removal of water inlet ............................ 13-31
Disassembly of engine ................................... 13-13 Removal of oil pan heater
Steam cleaning of engine ......................... 13-13 (If applicable) .......................................... 13-31
Removal of starting motor ........................ 13-13 Removal of oil pan ................................ 13-31-1
Weight of engine ........................................ 13-13 Removal of oil pan suction tube .......... 13-31-1
Installation to engine stand ....................... 13-13 Removal of rear seal cover ..................... 13-32
Draining oil ................................................. 13-14 Removal of camshaft ............................... 13-32
Removal of rear lifting bracket ................. 13-14 Removal of tappet .................................... 13-34
Removal of belt .......................................... 13-14 Removal of oil pump ............................... 13-34
Removal of fan pulley ................................ 13-15 Removal of timing pin housing .............. 13-35
Removal of vibration damper, Removal of gear housing ........................ 13-35
crankshaft pulley ...................................... 13-15 Removal of balancer ................................ 13-36
Removal of belt tensioner ......................... 13-15 Removal of piston connecting rod ......... 13-38
Removal of fan hub ................................... 13-16 Removal of crankshaft ............................. 13-40
Removal of alternator ................................ 13-16 Removal of turbocharger
Removal of thermostat .............................. 13-17 lubrication drain tube ............................ 13-42
Removal of turbocharger Removal of cylinder block
(engine with turbocharger) ..................... 13-17 from engine stand .................................. 13-42
Removal of exhaust manifold ................... 13-19 Assembly of engine ..................................... 13-43
Removal of fuel filter ................................. 13-19 Preparation for assembly
Removal of fuel filter head ........................ 13-20 of cylinder block ..................................... 13-43
Removal of fuel piping .............................. 13-20 Installation of tappet ................................ 13-43
Removal of dipstick ................................... 13-22 Installation of crankshaft ......................... 13-44
Removal of intake manifold cover ............ 13-22 Installation of piston and
Removal of after cooler connecting rod assemblies ................... 13-48
(engine with after cooler) ........................ 13-23 Installation of piston and
Removal of cylinder head cover ............... 13-23 connecting rod assembly ...................... 13-48
Removal of fuel injection nozzle ............... 13-23 Installation of gear housing .................... 13-52
Removal of rocker lever ............................ 13-24 Installation of oil pump ........................... 13-53
Removal of push rod ................................. 13-25 Installation of camshaft ........................... 13-54
Removal of cylinder head ......................... 13-25 Installation of timing pin ......................... 13-57
Removal of front cover .............................. 13-25 Installation of balancer ............................ 13-60
Removal of water pump ............................ 13-26 Installation of rear oil seal ....................... 13-64
Removal of flywheel .................................. 13-26 Installation of oil pan suction tube ......... 13-65
Removal of flywheel housing ................... 13-27 Installation of oil pan ............................... 13-66
Removal of components Installation of oil pan heater
(compressor, hydraulic pump, etc.) ........ 13-27 (If applicable) .......................................... 13-67
102 SERIES 13-1

(23)
Installation of oil cooler ........................... 13-67 Removal .................................................. 13-110

Installation of coolant heater Cleaning .................................................. 13-110
(If applicable) ....................................... 13-67-1 Installation .............................................. 13-110
Installation of oil filler port ................... 13-67-1 Air crossover tube ...................................... 13-111
Installation of feed pump ........................ 13-68 Cleaning .................................................. 13-111
Installation of tappet cover ..................... 13-68 Inspection ............................................... 13-111
Installation of fuel injection pump Exhaust group ............................................ 13-112
(Bosch A, Zexel A) .................................. 13-69 Disassembly and assembly drawing .... 13-112
Installation of components Outline of exhaust manifold ................. 13-113
(compressor, hydraulic pump, etc.) ...... 13-74 Replacement of exhaust
Installation of flywheel housing ............. 13-74 manifold, gasket ....................................... 13-114
Installation of flywheel ............................ 13-75 Removal .................................................. 13-114
Installation of water pump ...................... 13-76 Cleaning and inspection ........................ 13-114
Installation of front cover ........................ 13-76 Installation .............................................. 13-114
Installation of cylinder head .................... 13-78 Replacement of exhaust manifold .......... 13-115
Installation of push rod ........................... 13-79 Removal .................................................. 13-115
Installation of rocker lever ....................... 13-79 Cleaning .................................................. 13-115
Tightening of cylinder head .................... 13-81 Installation .............................................. 13-116
Adjusting valve clearance ....................... 13-83 Inspection ............................................... 13-116
Installation of fuel injection nozzle ......... 13-85 Replacement of turbocharger ................... 13-117
Installation of cylinder head cover ......... 13-86 Removal .................................................. 13-117
Installation of intake manifold cover ...... 13-86 Installation .............................................. 13-118
Installation of fuel filter head .................. 13-88 Turbocharger mounting stud
Installation of exhaust manifold ............. 13-89 (engine with turbocharger) ...................... 13-121
Installation of turbocharger Replacement ........................................... 13-121
(engine with turbocharger) ................... 13-90 Cylinder block group .................................. 13-122
Installation of thermostat ........................ 13-93 Disassembly and assembly drawing .... 13-122
Installation of crankshaft pulley, Outline of cylinder block group ............ 13-125
vibration damper ................................... 13-94 Outline of camshaft ............................... 13-125
Installation of fan hub .............................. 13-94 Outline of crankshaft ............................. 13-125
Installation of belt tensioner ................... 13-94 Outline of cylinder block ....................... 13-125
Installation of water inlet ......................... 13-95 Outline of oil seal ................................... 13-125
Installation of alternator .......................... 13-95 Replacement of front oil seal .................. 13-126
Installation of belt .................................... 13-96 Removal .................................................. 13-126
Installation of oil filter .............................. 13-97 Cleaning and inspection ........................ 13-127
Removal of engine from engine stand ... 13-97 Installation .............................................. 13-127
Installation of starting motor .................. 13-97 Replacement of rear oil seal .................... 13-129
Intake group .................................................. 13-98 Outline of piston .................................... 13-131
Disassembly and assembly drawing ...... 13-98 Outline of vibration damper .................. 13-131
Outline .................................................... 13-100 Check list for cylinder block group ....... 13-132
Replacement of turbocharger Cylinder block ............................................. 13-133
(engine with turbocharger) ...................... 13-101 Inspection before disassembly ............. 13-133
Removal .................................................. 13-101 Disassembly of cylinder block .............. 13-133
Installation .............................................. 13-102 Cleaning of cylinder block ..................... 13-135
Cleaning and inspection ........................ 13-104 Inspection of cylinder block .................. 13-138
Replacement of aftercooler, gasket Removal of glaze from cylinder bore ..... 13-140
(engine with aftercooler) ..................... 13-106 Disassembly ........................................... 13-140
Removal .................................................. 13-106 Inspection ............................................... 13-141
Cleaning .................................................. 13-106 Removal of glaze .................................... 13-141
Installation .............................................. 13-107 Cleaning .................................................. 13-144
Cleaning and inspection ........................ 13-108 Assembly ................................................ 13-145
Assembly ................................................ 13-108 Removal of glaze from cylinder block ...... 13-146
Replacement of intake connector ............. 13-109 Replacement of plug ................................ 13-149
Removal and installation ....................... 13-109 Removal .................................................. 13-149
Air connector .............................................. 13-109 Cleaning and inspection ........................ 13-149
Cleaning .................................................. 13-109 Installation .............................................. 13-150
Inspection ............................................... 13-109 Replacement of cap .................................. 13-150
Replacement of intake Removal .................................................. 13-150
manifold cover, gasket ............................. 13-109 Cleaning .................................................. 13-151
13-2 102 SERIES

(23)
Installation .............................................. 13-151 Assembly of piston connecting rod ..... 13-217

Installation of cup plug .......................... 13-152 Inspection of piston ring gap ................ 13-218
Installation of cap and plug ..................... 13-154 Installation of piston ring ...................... 13-219
Installation of camshaft cup .................. 13-156 Installation of piston connecting rod ... 13-220
Installation of camshaft bushing .......... 13-157 Replacement of connecting rod .............. 13-224
Replacement of dipstick tube ................ 13-158 Removal .................................................. 13-224
Storing cylinder block ............................ 13-159 Cleaning and inspection ........................ 13-225
Crankshaft ................................................... 13-159 Installation .............................................. 13-227
Replacement of main bearing ............... 13-160 Replacement of connecting
Cleaning of crankshaft ........................... 13-165 rod bearing ........................................... 13-228
Installation of crankshaft ....................... 13-165 Removal .................................................. 13-228
Replacement of crankshaft gear ........... 13-166 Cleaning and inspection ........................ 13-230
Replacement of camshaft and tappet .. 13-168 Installation .............................................. 13-231
Removal of camshaft ............................. 13-168 Disassembly of piston
Removal of tappet .................................. 13-169 connecting rod ..................................... 13-234
Inspection of tappet ............................... 13-171 Cleaning of piston, pin,
Standards for pitting when reusing ..... 13-173 connecting rod ..................................... 13-235
Standard for deterioration (breakage) Inspection of piston ............................... 13-236
of tip ...................................................... 13-174 Inspection of piston pin ......................... 13-237
Inspection of camshaft bore ................. 13-177 Inspection of connecting rod ................ 13-237
Replacement of camshaft bushing ......... 13-177 Inspection of connecting
Installation of tappet .............................. 13-178 rod bearing clearance .......................... 13-237
Installation of camshaft ......................... 13-181 Assembly of piston connecting rod ..... 13-238
Cleaning of camshaft ............................... 13-183 Inspection of piston ring end gap ......... 13-239
Inspection of camshaft, gear ................. 13-184 Installation of piston ring ...................... 13-240
Replacement of camshaft, gear ................ 13-186 Balancer ...................................................... 13-241
Cleaning and inspection ........................ 13-187 Disassembly ........................................... 13-241
Installation .............................................. 13-188 Assembly ................................................ 13-244
Replacement of timing pin ........................ 13-190 Gear housing .............................................. 13-251
Replacement of gear housing, gasket ...... 13-191 Replacement of gear cover ...................... 13-251
Removal .................................................. 13-191 Removal .................................................. 13-251
Cleaning and inspection ........................ 13-192 Cleaning and inspection ........................ 13-252
Repair of oil pan gasket ......................... 13-192 Installation .............................................. 13-252
Installation .............................................. 13-193 Installation of gear cover ....................... 13-254
Repositioning of timing pin .................. 13-196 Inspection of gear housing
Replacement of camshaft gear ............... 13-201 and timing pin ...................................... 13-256
Removal .................................................. 13-201 Disassembly of gear housing ............... 13-256
Installation (shrink-fitting method) ....... 13-202 Replacement of fuel injection
Installation pump mounting stud ........................... 13-257
(method using special tool) ................ 13-203 Replacement of engine name plate ...... 13-257
Installation of camshaft Cylinder head .............................................. 13-260
mounting bolts ..................................... 13-205 Disassembly and assembly drawing .... 13-260
Replacement of vibration damper, Outline ....................................................... 13-262
crankshaft pulley ...................................... 13-206 Replacement of cylinder head ................. 13-263
Removal .................................................. 13-206 Removal .................................................. 13-263
Inspection of rubber damper ................ 13-206 Inspection before disassembly
Installation .............................................. 13-207 of cylinder head ................................... 13-266
Inspection of viscous damper ............... 13-207 Disassembly of cylinder head ............... 13-267
Vibration damper (rubber type) ............ 13-209 Cleaning of cylinder head ..................... 13-268
Cleaning and inspection ........................ 13-209 Inspection of valve ................................. 13-270
Piston, pin, connecting rod ........................ 13-211 Inspection of valve guide ...................... 13-271
Replacement of piston and ring ........... 13-211 Inspection of cylinder deck ................... 13-271
Removal of piston connecting rod ....... 13-212 Inspection of valve seat ......................... 13-272
Disassembly of piston Standards for cracks in cylinder
connecting rod ..................................... 13-214 head when reusing .............................. 13-272
Cleaning of piston, pin, Replacement of valve spring ................ 13-273
connecting rod ..................................... 13-214 Assembly of cylinder head .................... 13-273
Inspection of piston ............................... 13-215 Installation of cylinder head .................. 13-274
Inspection of piston pin ......................... 13-216 Adjusting valve clearance ..................... 13-278
102 SERIES 13-3

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Installation of themostat ....................... 13-279 Installation ............................................ 13-321

Installation of fan hub ............................ 13-279 Replacement of flywheel housing ........ 13-324
Installation of belt tensioner ................. 13-280 Removal ................................................ 13-324
Installation of alternator ........................ 13-280 Cleaning and inspection ...................... 13-325
Installation of drive belt ......................... 13-281 Installation
Inspection before disassembly ............. 13-281 (dry clutch specification) ................... 13-326
Disassembly of cylinder head ............... 13-282 Inspection of radial runout
Cleaning of cylinder head ..................... 13-283 of flywheel housing ........................... 13-327
Inspection of valve ................................. 13-285 Inspection of face runout
Inspection of valve guide ...................... 13-286 of flywheel housing ........................... 13-329
Inspection of cylinder head Installation (wet clutch specification) . 13-330
combustion deck .................................. 13-286 Inspection ............................................. 13-332
Inspection valve seat ............................. 13-287 Installation ............................................ 13-333
Standards for cracks Front support ............................................ 13-334
in cylinder head when reusing ........... 13-287 Cleaning and inspection ...................... 13-334
Replacement of valve spring ................ 13-288 Removal of engine ................................... 13-335
Replacement of cap ............................... 13-288 Inspection of engine mount .................... 13-337
Polishing valve ....................................... 13-290 Installation of engine ............................... 13-338
Polishing valve seat ............................... 13-291 Oil pan and suction tube .......................... 13-342
Calculating grinding depth and Disassembly and assembly drawing ... 13-342
measuring depth of valve ................... 13-292 Replacement of oil pan,
Assembly of cylinder head .................... 13-296 suction tube, gasket ............................... 13-343
Rocker lever ................................................ 13-298 Cleaning and inspection ...................... 13-345
Disassembly and assembly drawing .... 13-298 Regulator valve ......................................... 13-346
Outline .................................................... 13-300 Replacement of regulator valve,
Replacement of rocker lever spring ................................................. 13-346
and push rod ........................................ 13-301 Cleaning and inspection ...................... 13-346
Removal .................................................. 13-301 Oil filter bypass valve ............................... 13-349
Disassembly of rocker lever .................. 13-302 Replacement ......................................... 13-349
Cleaning of rocker lever ........................ 13-303 Oil cooler ................................................... 13-350
Inspection of rocker lever ...................... 13-303 Disassembly and assembly drawing ... 13-350
Assembly of rocker lever ....................... 13-304 Replacement of oil cooler core,
Installation of rocker lever ..................... 13-305 gasket .................................................. 13-351
Disassembly of rocker lever .................. 13-307 Cleaning ................................................ 13-353
Cleaning of rocker lever, Inspection ............................................. 13-354
rocker lever shaft ................................. 13-308 Oil pump ................................................... 13-355
Inspection of rocker lever ...................... 13-308 Disassembly and assembly drawing ... 13-355
Inspection of rocker lever shaft ............ 13-309 Replacement of oil pump .................... 13-356
Assembly of rocker lever ....................... 13-309 Cleaning and inspection ...................... 13-357
Tappets and push rods ............................... 13-311 Installation of oil pump ....................... 13-360
Disassembly and assembly drawing .... 13-311 Inspection ............................................. 13-361
Outline .................................................... 13-312 Fuel injection pump group ...................... 13-365
Cleaning of push rod ................................ 13-313 Disassembly and assembly drawing ... 13-365
Inspection of push rod ........................... 13-313 Fuel injection nozzle group ...................... 13-366
Installation of push rod ......................... 13-313 Disassembly ......................................... 13-367
Inspection of tappet ............................... 13-314 Cleaning and inspection ...................... 13-368
Engine mount group .................................. 13-316 Assembly .............................................. 13-370
Outline of flywheel housing .................. 13-316 Feed pump
Outline of flywheel, ring gear ............... 13-316 (cylinder block mount type) ................... 13-373
Outline of front support ......................... 13-316 Replacement of feed pump
Flywheel, ring gear ..................................... 13-317 (diaphragm type) ............................... 13-373
Inspection of flywheel, ring gear .......... 13-317 Replacement, assembly of feed pump
Replacement of flywheel, ring gear ..... 13-317 (piston type) .......................................... 13-375
Flywheel housing ....................................... 13-319 Removal ................................................ 13-375
Replacement of rear oil seal .................... 13-319 Cleaning ................................................ 13-376
Removal .................................................. 13-319 Assembly .............................................. 13-376
Cleaning and inspection ........................ 13-321 Installation ............................................ 13-377
13-4 102 SERIES

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Cleaning and inspection ...................... 13-377 Installation ............................................ 13-422

Assembly (piston type) ........................ 13-379 Cleaning and inspection ...................... 13-424
Cleaning ................................................ 13-379 Inspection ............................................. 13-424
Assembly .............................................. 13-380 Alternator .................................................. 13-425
Replacement of fuel filter ........................ 13-380 Replacement of alternator ................... 13-425
Fuel piping ................................................ 13-382 Inspection ............................................. 13-426
Replacement of high-pressure Starting motor .......................................... 13-426
fuel piping (Bosch VE, Lucas CAV) ..... 13-382 Inspection ............................................. 13-427
Replacement of fuel supply piping
(Bosch VE, Lucas CAV) ...................... 13-383
Cleaning and inspection
of high-pressure fuel piping .............. 13-385
Replacement of fuel return piping
(Bosch VE, Lucas CAV) ...................... 13-386
of fuel drain piping ............................ 13-388
Replacement of low-pressure
fuel piping (Bosch VE, Lucas CAV) ... 13-388
of low-pressure fuel piping ............... 13-389
Replacement of air-fuel
ratio control tube (Bosch VE) ............ 13-390
Water pump .............................................. 13-391
Disassembly and assembly drawing ... 13-391
Replacement of water pump ............... 13-392
Inspection ............................................. 13-393
Fan hub ..................................................... 13-393
Replacement of fan pulley .................. 13-393
Replacement of fan hub ...................... 13-394
Inspection ............................................. 13-394
Disassembly ......................................... 13-395
Assembly .............................................. 13-396
Belt tensioner ............................................ 13-398
Replacement of belt ............................. 13-399
Replacement of belt tensioner ............ 13-399
Inspection ............................................. 13-399
Thermostat ................................................ 13-400
Replacement of thermostat ................. 13-401
Inspection ............................................. 13-402
Fan ............................................................. 13-404
Coolant ...................................................... 13-404
Accessory drive adapter .......................... 13-406
Cleaning ................................................ 13-407
Inspection ............................................. 13-407
Disassembly ......................................... 13-407
Assembly .............................................. 13-408
Disassembly of unloader valve,
cylinder head ...................................... 13-410
Cleaning ................................................ 13-411
Inspection ............................................. 13-412
Assembly .............................................. 13-416
Replacement air compressor .............. 13-419
Removal ................................................ 13-419
Inspection ............................................. 13-420
102 SERIES 13-5

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DISASSEMBLY AND ASSEMBLY DISASSEMBLY OF ENGINE
DISASSEMBLY OF ENGINE
STEAM CLEANING OF ENGINE
Warning: When cleaning with steam, wear protec-
tive clothing, safety glasses, and face
shield. Hot steam may cause serious
burns.
Caution: Fit covers to the openings of the engine
and to the electrical components, and be
careful not to get water on these parts.
Use steam to clean off any excessive dirt on the

outside of the engine.
REMOVAL OF STARTING MOTOR

10 mm
Remove the starting motor.
WEIGHT OF ENGINE (REFERENCE

VALUE NOT INCLUDING AUXILIA-
RIES SUCH AS MUFFLER)
3822512 Engine lifting equipment
0 4D102 engine (wet): 325 - 350 kg
0 6D102 engine (wet): 410 - 440 kg
INSTALLATION TO ENGINE STAND

18 mm, engine rebuilding stand, adapter (795-
799-1160)
Install the engine to the rebuilding stand.
3 : 77 Nm{7.9 kg}
Installation hardware: M12 x 1.75
102 SERIES 13-13

2
DRAINING OIL
22 mm
Remove the drain plug.
A drain pan with a 30 liter capacity is sufficient.
REMOVAL OF REAR LIFTING

BRACKET
18 mm
Remove the rear lifting bracket from the cylinder
head.
REMOVAL OF BELT
If excessive force is applied to the tensioner in the
opposite direction from winding in or when the
tensioner has been wound in to the normal stop
position, there is danger that the tensioner arm may
break.
Warning : Make sure that the wrench is secured
at the portion square hole before rotat-
ing it. (The spring of the tensioner is
strong. If the wrench is loosely inserted,
the wrench may accidentally come off
while being rotated and it is extremely
dangerous.)
: After removing the drive belt, return the
tensioner slowly with care.
: Be careful not to get your fingers caught
between the pulley and drive belt dur-
ing work.
Caution: Do not put your hand near the path of
the tensioner when it is under the force
of the spring.
Loosen the tension with a 1/2 inch or 3/8 inch square
headed wrench, then remove the drive belt.
Operating hint: Remove the drive belt after loos-

ening the vibration damper crankshaft and hub
pulley mounting bolt.
13-14 102 SERIES

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REMOVAL OF FEED PUMP

(ENGINE MOUNT TYPE)
10 mm
Remove the fuel feed pump, spacer, and gasket.
Caution: For details of the procedure for testing the
fuel feed pump, see Component.
REMOVAL OF TAPPET COVER

10 mm
Remove the tappet cover and gasket.
REMOVAL OF OIL FILLER

18 mm
If it is installed, remove the mounting bolts, side
oil filler assembly, and rectangular ring seal. On
some engines, the oil drain connection for the air
compressor is also installed at this position. Re-
move the connection and the rectangular ring seal.
REMOVAL OF COOLANT HEATER

(IF APPLICABLE)
Remove the coolant heater from the block.
13-30 102 SERIES

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REMOVAL OF OIL COOLER

90 - 95 mm {3-1/2 - 3-7/8 in} filter wrench
Remove the oil filter cartridge.
10 mm
Remove the mounting bolts, oil cooler cover, cover
gasket, oil cooler, and cooler gasket.
Caution: For details of the procedure for inspec-
tion, see Component.
REMOVAL OF WATER INLET

13 mm
Remove the coolant inlet port connection and rect-
angular ring seal.
REMOVAL OF OIL PAN HEATER

(IF APPLICABLE)
Remove the heater element.
102 SERIES 13-31

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REMOVAL OF OIL PAN

10 mm
Rotate the engine on the stand and remove the oil
pan.
REMOVAL OF OIL PAN SUCTION

TUBE
10 mm
Remove the suction tube and gasket.
13-31-1 102 SERIES

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DISASSEMBLY AND ASSEMBLY ASSEMBLY OF ENGINE
22 mm
Install the drain plug and a new sealing washer.
3 : 102-1: 80 Nm {8.2 kgm}
102-2: 59 Nm {6 kgm}
INSTALLATION OF OIL PAN

HEATER (IF APPLICABLE)
Install the heater element.
3 : 80 Nm {8.2 kgm}
INSTALLATION OF OIL COOLER

Caution: When installing a new element, always
remove the transportation plug.
Insert two mounting bolts from the oil cooler cover.
Assemble the cooler cover gasket, oil cooler gas-
ket, and oil cooler cover.
10 mm
Install the assembly to the cylinder block.
3: 24 Nm {2.4 kgm}
102 SERIES 13-67

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INSTALLATION OF COOLANT
HEATER (IF APPLICABLE)
Apply pipe sealant (part number 3375066 or the
equivalent) to threads of the coolant heater.
Install the coolant heater.
3 : 55 Nm {5.6 kgm}
INSTALLATION OF OIL FILLER

PORT
15 mm
If it is installed to the side, install the chamfered oil
filler port assembly and O-ring.
3: 43 Nm {4.4 kgm}
13-67-1 102 SERIES

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13 mm
Set the belt tensioner on the bracket and secure it
with the mounting bolts.
3: 43 Nm {4.4 kgm}
Caution: There are also tensioners that are tight-
ened by bolts to the bracket at two places.
Install to the specified position.
INSTALLATION OF WATER INLET

Caution: Do not tighten at this point. Avoid radial
misalignment and overload on the bot-
tom support mounting gear on the alter-
nator. Leave the mounting bolts loosened
until the alternator parts are installed.
Install the cooling water inlet port connection and
sealing ring.
INSTALLATION OF ALTERNATOR
10 mm
Assemble the alternator bracket to the thermostat
housing.
3: 24 Nm {2.4 kgm}
Set the alternator on the bracket, and secure with

the mounting bolts and spacers.
Do not tighten at this point.
102 SERIES 13-95

2
Caution: Do not tighten at this point. Avoid radial

runout and overload on the bottom sup-
port mounting lug of the alternator.
Leave the mounting bolts loosened until
the alternator parts are installed.
Install the alternator link.
Check the alternator pulley visually or use a straight

edge to check if the center is aligned with the other
pulleys and that it is parallel to the front face of the
block.
After assembling all parts, tighten the mounting

bolts in the following order.
1. Alternator bracket mounting bolts for alter-
nator
2. Alternator mounting bolts for bottom brace
3. Cooling water inlet port mounting bolts for
alternator
4. Block mounting bolts for cooling water inlet
port
Caution: The size of the wrench and the torque
value depend on the alternator manufac-
turer and the model. For details of the
torque value, see Engine Components.
INSTALLATION OF BELT
3/8 inch square drive
Raise the tensioner and install the belt.
dangerous.)
ing work.
Operating hint:
If it is difficult to install the drive belt (the belt
may be too short), set the belt on top of the
grooved pulley and support the tensioner while
sliding the belt over the water pump pulley.
13-96 102 SERIES

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DISASSEMBLY AND ASSEMBLY CYLINDER BLOCK GROUP
OUTLINE OF CYLINDER BLOCK

GROUP
There are two types of engines in the 102 series: OUTLINE OF OIL SEAL
the 4-cylinder engine and the 6-cylinder engine.
The crankshaft seals on the 102 series engines all
Most of the parts are common for both the 4-cylin- are of the Teflon lay-down lip (scroll) type. With
der engine and 6-cylinder engine (for example, pis- this type of seal, there is no spring behind the seal-
tons, rings, connecting rods, water pump) ing lip. The seal lip is a thin but sturdy Teflon piece.
Generally speaking, the parts that are different for Dry the Teflon seal before installing it. Do not add
the 4-cylinder engine and 6-cylinder engine are the oil to the seal lip or shaft.
parts that differ because of the different number of
If the shaft is rotated 2 or 3 turns, a thin film of
cylinders (for example, crankshaft, block casting,
Teflon will flow out from the seal lip to the shaft.
cylinder head)
If the shaft or seal are not cleaned and dry, there
will be no flow of Teflon and this will result in leak-
OUTLINE OF CAMSHAFT age from the seal.
The end clearance of the camshaft is determined
by the clearance between the camshaft and the
thrust plate.
Replace the camshaft if it is worn or if the fuel feed
pump lobe or valve lobe are worn. We do not rec-
ommend grinding of the camshaft lobe.
OUTLINE OF CRANKSHAFT
The crankshaft is a balanced, forged steel unit with
hardening treatment given for the whole thickness.
The crankshaft for the 4-cylinder engine has 5 main
bearing journals and the crankshaft for the 6-cylin-
der engine has 7 main bearing journals. Except
for the No. 4 journal, which has an upper bearing
shell with a flange, all the other upper main bear-
ing shells are the same. The upper bearing flange
controls the end thrust of the crankshaft.
When carrying out maintenance, an oversize main
bearing, thrust bearing, and connecting rod bear-
ing can be used. If any part requires grinding, we
recommend that all the main bearings or connect-
ing rod journals should be ground.
OUTLINE OF CYLINDER BLOCK

The oil cooler, thermostat seat, coolant bypass line,
water pump volute, oil pump housing, water pump
inlet port, and bore type piston cylinder are installed
to the cylinder block. Space is provided between
the cylinders for use when maintenance is required
and room is left to make it possible to use a dry
liner.
102 SERIES 13-125

2
REPLACEMENT OF FRONT OIL

SEAL
REMOVAL
Remove the drive belt.
dangerous.)
ing work.
Caution: If the crankshaft pulley is loosened be-
fore the belt is removed, the belt can be
removed easily.
15 mm
Remove the crankshaft pulley.
Remove the front cover. For details of the proce-

dure.
Remove the oil seal from the gear cover. Support

the gear cover, set the oil seal facing to the front,
and push out from the rear of the cover.
13-126 102 SERIES

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Install the drive belt.

dangerous.)
ing work.
Tighten the crankshaft pulley mounting bolts.

3: 125 Nm {12.7 kgm}
REPLACEMENT OF REAR OIL SEAL

Preparatory work:
Remove the transmission.
Remove the flywheel.
1/8 inch drill

Make 2 holes 180 x apart in the seal carrier.
102 SERIES 13-129

(21)
No. 10 sheet metal screw, slide hammer dent

puller
Remove the rear seal.
Caution: To prevent leakage from the seal, make

sure that there is absolutely no oil on the
crankshaft seal lip or seal surface.
Clean the crankshaft seal surface and dry it.
Install the seal pilot (included in the replacement

kit) to the crankshaft. Push the seal against the
pilot and crankshaft.
Remove the seal pilot.
Using the alignment tool, install the seal to the

proper depth in the housing. Tap with a hammer
to knock the seal into the housing to a point where
the alignment tool contacts the housing.
Tap the tool at the 12 oclock, 3 oclock, 6 oclock,
and 9 oclock positions to push the seal in uni-
formly. Be careful not to bend the seal carrier.
13-130 102 SERIES

2
DISASSEMBLY AND ASSEMBLY REPLACEMENT OF GEAR HOUSING, GASKET
Disassemble the camshaft gear installer, and re-

move the camshaft retainer.
INSTALLATION OF CAMSHAFT
MOUNTING BOLTS
Check that the gear is seated in front of the cam-
shaft shoulder.
Using a 0.001 inch clearance gauge, check if the
clearance gauge can be inserted between the cam-
shaft gear and camshaft gear shoulder. If the clear-
ance gauge can be inserted, the camshaft gear is
not properly seated.
Insert the camshaft mounting bolt in the gear re-

tainer, then insert the mounting bolt and retainer
assembly to the camshaft.
Tighten the camshaft mounting bolt to 27 Nm {2.8

kgm}.
102 SERIES 13-205

2
REPLACEMENT OF GEAR HOUSING, GASKET
REPLACEMENT OF VIBRATION DAMPER,
DISASSEMBLY AND ASSEMBLY CRANKSHAFT PULLEY
After tightening the camshaft, tighten the mount-

ing bolt a further 180.
REPLACEMENT OF
VIBRATION DAMPER,
CRANKSHAFT PULLEY
REMOVAL
dangerous.)
ing work.
15 mm
Remove crankshaft pulley and vibration damper.
(On the 6-cylinder engine, the vibration damper
forms one unit with the crankshaft pulley.)
INSPECTION OF RUBBER DAMPER

Check index line (A) of inertia material (C) and
damper hub (B). If the alignment of both lines is
more than 1.59 mm apart, replace the damper.
Check vibration damper hub (B) for cracks.
If there are any cracks in the hub, replace the
damper.
13-206 102 SERIES

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INSTALLATION
Check for deterioration of the rubber. If the rubber
is damaged or missing, or the elastic material is
more than 3.18 mm {1/8 in} lower than the metal
surface, replace the damper.
Caution: Check the forward movement of the
damper ring at the hub. If there is any
movement, replace the damper.
INSPECTION OF VISCOUS
DAMPER
Check the mounting web for cracks. Check for
dents or swelling in the surface of the housing. If
such defects are found, replace the damper. See
this section for details of the replacement proce-
dure.
Remove the viscous damper. See this section for

details of the replacement procedure.
Clean the damper with detergent.
The viscous damper is filled with silicon liquid.

After many hours of use, the silicon liquid will
become thicker and will expand. When judging if
the damper thickness is correct, remove the paint
from the damper in 4 places on either side of the
damper. Measure the damper thickness at the 4
places and note down the measurement. Measure
the thickness at 3.175 mm from the outside of the
damper. If the thickness varies by more than 0.25
mm, replace the damper.
102 SERIES 13-207

2
Spray developer type SKD-NF or the equivalent into

the damper to carry out a color check. Put the
damper in an oven (set with the rolled lip at the
bottom) and heat for 2 hours at 93 C.
Caution: Wear protective gloves to prevent burns

when handling the heated parts.
Remove the damper from the oven and inspect for
leakage of fluid. If there is any leakage, replace
the damper.
See this section for details of the replacement pro-
cedure.
15 mm
Install the crankshaft pulley and viscous damper.
At this point, do not tighten the mounting bolts to
the specified tightening torque.

dangerous.)
ing work.
13-208 102 SERIES

(21)
Tighten the mounting bolts of the crankshaft pul-

ley and viscous damper.
3: 125 Nm {12.7 kgm}
102 SERIES 13-208-1

(21)
DISASSEMBLY AND ASSEMBLY GEAR COVER
GEAR COVER
REPLACEMENT OF GEAR COVER
REMOVAL
dangerous.)
ing work.
15 mm
Remove the crankshaft pulley.
10 mm
If necessary, remove the hub pulley.
10 mm
Remove the front gear cover.
102 SERIES 13-251

(21)
CLEANING AND INSPECTION

Clean the gear cover and gear housing gasket sur-
face.
Check the gear cover for cracks or damage.
Caution: Before installing the gear cover, clean and

dry the crankshaft, and remove all oil and
grease. If the seal surface is not properly
cleaned, it will cause oil leakage.
INSTALLATION
Install a new seal to the gear cover.
13-252 102 SERIES

2
Coat only the cover side of the front cover gasket

thinly with a bead of Three Bond.
Caution: At this point, do not remove the plastic
seal pilot tool from the oil seal. Using the
plastic seal pilot tool, guide the seal on to
the crankshaft.
Install the gasket and front cover to the engine.
Tighten the front cover mounting bolts.

Remove the plastic seal pilot tool from the crank-
shaft.
3: 24 Nm {2.4 kgm}
15 mm
Install the crankshaft pulley. At this point, do not
tighten the mounting bolts to the specified torque.

dangerous.)
ing work.
102 SERIES 13-253

(21)
Tighten the crankshaft pulley mounting bolts.

3: 125 Nm {12.7 kgm}
INSTALLATION OF GEAR COVER

Lubricate the front gear train with clean oil.
Caution: If the seal lip and crankshaft seal surface

are not dry and completely free of oil, it
will cause oil leakage.
Clean the crankshaft front seal mounting surface.

Caution: When removing and installing the gear
cover, always replace the front seal.
10 mm
Coat only the front cover side of the gasket thinly
with Three Bond.
Caution: At this point, do not remove the plastic
seal pilot tool from the oil seal. Using the
plastic seal pilot tool, guide the seal on to
the crankshaft.
Install the gasket and front cover.
13-254 102 SERIES

2
Tighten the front cover mounting bolts.

Remove the pilot from the crankshaft.
3: 24 Nm {2.4 kgm}
Install the front cover access cap and seal.
15 mm
Install the crankshaft pulley or vibration damper.
At this point, tighten the mounting bolts partially.
1/2 inch square head drive

Raise the belt tensioner and install the belt.
dangerous.)
ing work.
102 SERIES 13-255

(21)
15 mm
Tighten the crankshaft pulley.
3: 125 Nm {12.7 kgm}
INSPECTION OF GEAR HOUSING AND

TIMING PIN
Check the gear housing visually for cracks or dam-
age.
Check the seal surface.
Check the timing pin housing and pin for damage.
DISASSEMBLY OF GEAR HOUSING

If there is no damage or leakage, or the gear hous-
ing is not replaced, do not remove the timing pin
housing.
13-256 102 SERIES

2
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REPLACEMENT OF CYLINDER HEAD

REMOVAL
Preparatory work:
Drain the coolant.
Remove the coolant and heater hoses.
Remove the turbocharger and exhaust manifold.
Remove the injectors and fuel line.
Remove the rocker lever and push tube.
102 SERIES 13-263

2
10 mm
Remove the intake manifold cover and intake heater
(when installed).
When installing, be sure that the manifold cover is
facing in the correct direction.

Warning : Make sure that the wrench is secured at
the portion square hole before rotating
it. (The spring of the tensioner is strong.
If the wrench is loosely inserted, the
wrench may accidentally come off while
being rotated and it is extremely dan-
gerous.)
ing work.
13 mm
Remove the belt tensioner.
5 mm hexagon wrench
Remove the belt tensioner bracket.
13-264 102 SERIES

(21)
Tighten the mounting bolts in the following order.

1. Alternator bracket mounting bolts for alter-
nator
2. Alternator mounting bolts for bottom brace
3. Cooling water inlet port mounting bolts for
alternator
4. Block mounting bolts for cooling water inlet
port
Caution: The size of the wrench and the torque
value depend on the alternator manufac-
turer and the model. For details of the
torque value, see Engine Components.
INSTALLATION OF DRIVE BELT

Raise the tensioner and install the belt.
dangerous.)
ing work.
Operating hint:
If it is difficult to install the drive belt (the belt may
be too short), fit the belt on the grooved pulley and
raise the tensioner while sliding the belt over the
water pump pulley.
INSPECTION BEFORE DISASSEMBLY

Wash the cylinder head with detergent.
Check visually for damage which makes it impos-

sible to reuse the cylinder head. Check for dam-
age and cracks in the combustion surface that will
cause loss of sealing.
102 SERIES 13-281

(21)
DISASSEMBLY OF CYLINDER HEAD

Make marks on the valves to distinguish the posi-
tion.
Compress the valve spring and remove the valve

stem collet.
Remove the valve spring, then remove the retainer

and spring.
Remove the other collets, retainers, springs, and

valves.
When measuring, keep the valves on the labeled
rack in sets with their companion seat.
13-282 102 SERIES

2
DISASSEMBLY AND ASSEMBLY BELT TENSIONER
REPLACEMENT OF BELT
3/8-inch square head
Raise the tensioner and remove the belt.
dangerous.)
ing work.
Caution: The belt tensioner is a spring type, so
separate it from the drive belt and rotate
it. If the direction of rotation is mistaken,
the belt tensioner may be damaged.
REPLACEMENT OF BELT
TENSIONER
Preparatory work:
Remove the belt.
15 mm
Remove the mounting bolts, then replace the
tensioner.
3: 43 Nm {4.4 kgm}
INSPECTION
Check that there is no excessive wear and enlarge-
ment of the hole at the tensioner pivot tube por-
tion. If the tensioner is excessively worn, replace
it.
Rotate the bearing and check that there is no rough

portion and that it rotates freely.
102 SERIES 13-399

(21)
DISASSEMBLY AND ASSEMBLY THERMOSTAT
THERMOSTAT
DISASSEMBLY AND ASSEMBLY DRAWING
Index No. Part Name Qty Remarks
1 Thermostat housing 1
2 Thermostat housing gasket 1
3 Hexagonal mounting bolt 1 M8-1.25 x 35
4 Hexagonal mounting bolt 2 M8-1.25 x 70
5 Lifting bracket 1 M12-1.75 x 70
6 Thermostat cooling water 1
13-400 102 SERIES

0

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SEBM010023

01 GENERAL ............................................................................................................ 01-1

11 STRUCTURE AND FUNCTION ........................................................... 11-1

12 TESTING AND ADJUSTING ................................................................ 12-1

13 DISASSEMBLY AND ASSEMBLY ..................................................... 13-1

14 MAINTENANCE STANDARD ............................................................... 14-1

15 REPAIR AND REPLACEMENT OF PARTS .................................. 15-1

00-2 102 SERIES

( ) Page to be deleted Discard

Pages having no marks are those previously re-

LIST OF REVISED PAGES

102 SERIES 00-2-1

00-2-2 102 SERIES

102 SERIES 00-2-3

13-262 (2) 13-315 (2) 13-368 (2) 13-421 (2) 15-11

00-2-4 102 SERIES

IMPORTANT SAFETY NOTICE

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to keep

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL REVISED EDITION MARK

Chassis volume: Issued for every machine model REVISIONS

DISTRIBUTION AND UPDATING

Heavy parts (25 kg or more) must be lifted

If a part cannot be smoothly removed from the

The allowable load value is estimated to be one-

2) Sling wire ropes from the middle portion of the

METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER

Before carrying out the following work, release

For details, see TESTING AND ADJUSTING,

Even if the residual pressure is released from

2) Hold adapter (1) and push hose joint (2) into

3) After hose joint (2) is pushed into adapter (3),

4) Hold hose adapter (1) or hose (5) and pull it out.

2) After inserting the hose in the mating adapter

Used to prevent rubber gaskets,

Used in places requiring an imme-

Features: Resistance to heat and

Adhesive: Used as adhesive or sealant for

Polyethylene Used as sealant for machined

Holtz Used as heat-resisting sealant for

Quick hardening type adhesive

Quick hardening type adhesive

Loctite Polyethylene Resistance to heat, chemicals

Used as adhesive or sealant for

Used as sealant for various

Features: Silicon based, resist-

Ftures: Silicon based, quick hard-

Three bond Used as heat-resisting sealant for

Used as lubricant for sliding por-

SYG2-400LI General purpose type

SYG2-400CA Used for normal temperature,

Molybdenum 400 g Used for places with heavy load

STANDARD TIGHTENING TORQUE

6 10 13.2 1.4 1.35 0.15

27 41 1320 140 135 15

6 10 7.85 1.95 0.8 0.2

TABLE OF TIGHTENING TORQUES FOR FLARED NUTS

Thread diameter Width across flat Tightening torque

14 19 24.5 4.9 2.5 0.5

TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS

Thread diameter Width across flat Tightening torque